INDUSTRIAL RELIABILITY & MAINTENANCE
Downtime is not inevitable.
Aurelia keeps critical equipment running through condition-based monitoring, planned maintenance programs, and rapid-response repair — the same reliability engineering principles used across energy, aerospace, and heavy manufacturing, applied to your plant floor.
lost to unplanned downtime every week across U.S. manufacturing (≈$852M) — Fluke Reliability, 2025
BY THE NUMBERS
The cost of not knowing
Most plants still find out about a failure after it happens. Here is what that costs.
lost weekly to unplanned downtime across U.S. manufacturers (≈$852M).
Fluke Reliability, 2025 ↗of manufacturers have fully adopted predictive maintenance — most plants are still flying blind.
Fluke Reliability, 2025 ↗Nearly half of manufacturers report outages lasting up to 12 hours, and 15% endure incidents that stretch past 72 hours. Reactive repairs also routinely cost more than the same job done on a planned schedule, once secondary damage, expedited parts, and lost production are counted — the case for shifting spend upstream, from repair to reliability.
Rand figures converted from the original USD study at ≈R16.13/$1 (September 2026) for reference — the underlying study covers U.S. manufacturers.
STRATEGY COMPARISON
Three ways to maintain an asset
Every piece of equipment gets one of three treatments. The right one depends on what failure actually costs you.
Reactive Maintenance
Run to failure. Repairs happen only after the asset breaks down or stops performing — maximizing short-term use, at the cost of unplanned, disruptive downtime and higher repair costs from secondary damage.
- TimingAfter failure, unscheduled
- Cost profileHighest per-incident cost; secondary damage is common
- DowntimeUnplanned and disruptive to production
- Best fitLow-criticality, cheap-to-replace assets
MEASURE WHAT MATTERS
Calculate your OEE
Overall Equipment Effectiveness combines three losses into one number. Move the sliders to match your line.
OEE = Availability × Performance × Quality
CAPABILITIES
What we maintain, and how
A strategy assigned per asset, not a blanket schedule applied to everything on the floor.
CAP / 01
Preventive Programs
Scheduled inspection, lubrication, calibration, and parts replacement built around manufacturer specs and real duty cycles — not guesswork.
CAP / 02
Predictive & Condition Monitoring
Vibration analysis, infrared thermography, oil analysis, and ultrasonic testing to catch degradation before it becomes a failure.
CAP / 03
Reliability-Centered Maintenance
Failure-mode analysis that matches maintenance strategy to actual criticality and risk, asset by asset, not a single policy plant-wide.
CAP / 04
Emergency Response
Rapid-dispatch repair crews for the failures that happen anyway, with parts logistics built to minimize time to restart.
CAP / 05
Asset Lifecycle Management
Run, repair, or replace decisions backed by MTBF, MTTR, and total cost-of-ownership data instead of instinct.
CAP / 06
Compliance & Documentation
Inspection records, calibration certificates, and audit-ready maintenance logs, always current.
HOW WE WORK
Our process
The same four stages, repeated as a loop rather than a one-time project.
01
Assess
Baseline audit of asset criticality, failure history, and current maintenance state.
02
Plan
A strategy assigned per asset — reactive, preventive, or predictive — based on risk and cost.
03
Execute
Scheduled work orders, technician dispatch, and parts logistics, tracked to completion.
04
Monitor
Sensor data and inspection results feed back into the plan, continuously.
REFERENCE
The language of reliability
The five terms that come up in every maintenance conversation — and how they're actually calculated.
Higher is better. Used to judge how reliable a repairable asset is over time.
Lower is better. Measures how fast a team gets a failed asset back in service.
A single score for how much of an asset's full production potential is actually realized.
A structured process for choosing the right maintenance strategy for each specific failure mode.
A shop-floor philosophy where operators share responsibility for equipment condition, aiming at zero unplanned downtime.
The umbrella approach behind predictive maintenance: act on real sensor data, not a fixed calendar.
GET STARTED
Let's talk reliability.
Tell us what's running, and where it keeps failing. We'll start with an asset criticality review before recommending a single work order.
Response within one business day. No obligation.