As operations consultants, our firm gets involved with a project during startup (or during operations after startup) when there are significant problems surfacing, and the owner is either concerned, frantic, or both.
When called in to evaluate a situation, we usually undertake to identify the problems or shortcomings, understand the real needs of the facility, and determine the root causes of the problems and how they can be corrected and avoided. We have developed a detailed analysis procedure and have acquired considerable experience data. This accumulated history reveals one dominant scenario: instances where insufficient or inadequate thought and planning has been given to the maintenance of various elements of the facility. In a short time, items are failing or not operating properly, or need replacement.