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Improved System Performance and Dependability

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A critical piece of production equipment (so critical that on board inline spares were included) had undergone a remanufacture and redesign. System malfunction and dependability problems had gone unresolved for over a year delaying production and causing lost opportunity. The original vendor, consulting engineering companies and the internal engineering department had been unable to resolve the problem. Any solution was complicated by the explosion proof requirements of the application and heightened safety concerns due to the inherent danger of the manufacturing process.


  • An exhaustive study of the application was done. Including all component specifications.
  • The equipment was observed in operation and production and maintenance personnel were consulted.
  • A course of action which included:
    • Redesign of a circuit.
    • Replacement of misapplied components
    • Upgrade in filtration
    • Redesign of backup system
  • Maintenance and production personnel were trained in the function, proper maintenance and troubleshooting procedures of all components.


  • The system malfunctions due to inherent design were eliminated.
  • Component duty cycle was increased by 200+%
  • System downtime related to power unit failure was reduced to ZERO.