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Maintenance Failure Investigation
The maintenance was on schedule. The machine failed anyway.
Breakdowns after planned maintenance, repeat failures on the same equipment, a maintenance budget that grows while reliability falls. We investigate why maintenance is not working, for plants across Pakistan and the Gulf, and what will make it work.
Discuss this with usSince the 1990s
30
years investigating
250+
investigations closed, incl. HiPOs
15
countries served
20+
countries of lead seminars
100+
nationalities trained
B1 · WHY MAINTENANCE IS NOT WORKING
Why maintenance is not working Choose a case.
THE SYMPTOM
Same pump fails every few months.
WHAT WE USUALLY FIND
The failed part is replaced; the cause of the failure is never examined.
Illustrative cases, typical of what maintenance failure investigation uncovers.
B2 · WHAT WE LOOK AT
The maintenance was on schedule. A first call costs nothing, and we will tell you what the evidence needs to show.
B3 · ONE INVESTIGATION, MANY FINDINGS
You commission one investigation. You get a review of the whole system.
A typical example, based on many investigations. Not a single client’s case.
The P3i approach
How we investigate a maintenance failure. Fact-finding, not fault-finding.
Every P3i investigation is led by a senior investigator and supported by internationally qualified process specialists. You will not receive a list of people to blame, or a long list of generic actions. You will receive the facts, the proven causes, and a short plan that closes the gaps, in this case and across your system.
Independent
No products, repairs or contracts to sell you afterwards.
Senior-led
Thirty years of investigation, from the first call to the final briefing.
Beyond the event
Process specialists find the other cracks before they fail.
Ready to present
Written for boards, buyers, insurers and regulators.
How P3i does it for you
- 01
Read the maintenance history
Work orders, service reports and spares.
- 02
Find why maintenance did not prevent it
Planning, intervals, skills or spares.
- 03
Check condition monitoring
What was measured and what was ignored.
- 04
Review the system
Planning, reporting and escalation across the plant.
- 05
Fix the maintenance system
Actions with owners and a follow-up measure.
What you receive
Call us when
Free 30-minute case assessment.
Tell us what happened. In confidence, we will tell you what the investigation should cover, how long it will take and what to preserve today.
How we work with you
What happens after you call.
For a maintenance failure investigation, the first call covers what has happened, which records exist and who needs to be involved. From there, this is the usual pattern.
First hour
A call with a lead investigator. You leave it knowing what to preserve today and who to call next.
Day one
An investigator on site, anywhere in Pakistan. Scope and fixed fee agreed in writing.
Week one
A private briefing on early findings, so urgent risks are dealt with before the report is finished.
Weeks three to four
The final report, the wider system review and a remedial work plan, presented to your team.
After
We come back to check the actions were completed and actually worked.
Typical timings for a single-site event. Complex, multi-party matters take longer, and we tell you so on the first call.
What you receive
A full investigation report. This is only its first page.
The summary is what leadership reads first. Behind it sits the complete file: every witness heard, every document and record examined, and every finding tied to numbered evidence, so a board, an insurer, a buyer or a regulator can test it.
1 · Established sequence
2 · Causes
3 · Wider system findings
4 · Remedial work plan
Illustrative summary page. Report length and structure depend on the scope of each case.
Inside the full report
- 01Executive summary SHOWNThe findings and actions leadership needs, on one page. This is the page shown here.
- 02Terms of reference & scopeThe questions asked, the boundaries of the investigation and who commissioned it.
- 03MethodHow evidence was gathered, and which analysis methods were chosen for this case, and why.
- 04Verified chronologyThe sequence of events, reconstructed from records, data and accounts, minute by minute where it matters.
- 05Site & technical examinationScene, equipment, failed parts, measurements and photographs, with specialists where needed.
- 06Witness evidenceInterview schedule, accounts in summary, and where the witnesses agree and where they conflict.
- 07Documents & recordsPermits, procedures, maintenance, training, rosters, CCTV, tracker and control-system data reviewed.
- 08Causal analysisImmediate, underlying and system causes, each one tied to numbered evidence.
- 09System reviewWhere the same weaknesses exist elsewhere in the operation.
- 10Findings & conclusionsWhat is proven, what is probable, and what remains open, stated plainly.
- 11Recommendations & work planTargeted actions, each with an owner, a date and a test of whether it worked.
- 12AppendicesEvidence register, photograph log, interview records, drawings and data extracts.
Every action has an owner, a date and a test of whether it worked. The evidence stays indexed, so any reader can check how each conclusion was reached.
From our files
See all 16 cases → Client names, people, locations and dates removed.
QUESTIONS
What leadership teams ask us first.
We follow the manufacturer's schedule. Why is it failing?
Schedules assume particular conditions. Heat, dust, voltage and double shifts change them.
Can you review our whole maintenance system?
Yes. One repeated failure is often the best entry point to a full review.
Do you supply maintenance staff?
No. We investigate and recommend; your team or contractors carry out the work.