In asset-intensive industries, precision is paramount. Every operational process, from maintenance scheduling to resource planning, demands accuracy. Yet, even with the most well-designed systems, human error remains an ever-present risk – and its consequences can be severe.
For Enterprise Asset Management (EAM) organizations, these errors can lead to costly downtime, safety hazards, and reputational damage. Fortunately, modern software solutions can significantly reduce human error, safeguarding both operational performance and the bottom line.
Human Error in Action
History has shown that even the most sophisticated organizations are not immune to costly errors. Consider these high-profile examples:
- BP Deepwater Horizon (2010): A series of miscalculations and oversight contributed to one of the largest oil spills in history. The disaster led to 11 deaths, extensive environmental damage, and over $65 billion in fines and cleanup costs. Human error and poor decision-making were key contributors.
- NASA’s Mars Climate Orbiter (1999): A failure to convert units from imperial to metric caused the $125 million spacecraft to disintegrate upon entering Mars’ atmosphere. This fundamental oversight highlights how even seemingly minor calculation errors can lead to catastrophic results.
- Volkswagen Dieselgate Scandal (2015): Although deliberate deception was at play, the fallout also exposed gaps in compliance and testing procedures. The scandal cost Volkswagen over $30 billion and tarnished its reputation. Human factors in process adherence were significant.
While these examples span different industries, they underscore a universal truth: human error can be tragic and ruinously expensive.
Human Error in EAM Operations
For asset intensive organizations running SAP, human error often manifests in more subtle yet damaging ways.
Incorrect Data Entry
Entering the wrong maintenance date, misreporting asset status, or inputting inaccurate inventory levels can cause scheduling conflicts and resource misallocation. For example, an incorrect date could lead to preventive maintenance being skipped, or an inaccurate inventory count could result in critical spare parts being unavailable when needed. These data inaccuracies can snowball, creating bottlenecks that disrupt production schedules and erode operational efficiency.
Missed Preventative Maintenance
A technician overlooking a task or incorrectly logging work completion can result in equipment failure, unplanned downtime, and costly repairs. In asset-intensive environments, such lapses can lead to accelerated equipment wear and premature breakdowns. What could have been a simple lubrication task might escalate into a complete bearing failure, forcing a production halt and emergency repairs that inflate costs and stretch maintenance teams.
Work Order Confusion
Miscommunication between departments can lead to duplicate work orders or, worse, neglected tasks that impact production. Imagine a scenario where maintenance is scheduled on critical equipment, but the production team is unaware. This misalignment could result in halted production lines or, conversely, maintenance teams arriving to find equipment in active use, wasting time and resources. Duplicate work orders also consume manpower unnecessarily, while incomplete tasks expose the organization to potential failures.
Safety Risks
Failing to follow proper safety protocols during maintenance activities can endanger employees, potentially leading to workplace accidents and liability claims. Maintenance work often involves hazardous tasks such as working at heights, dealing with high voltages, or operating heavy machinery. A simple oversight, like forgetting to lockout/tagout equipment, can lead to serious injuries or fatalities. Beyond the human toll, such incidents can trigger investigations, legal action, and reputational damage.
These errors accumulate over time, eroding operational efficiency and inflating costs. In the worst cases, they can lead to catastrophic failures akin to those in the aforementioned examples.
Technology as a Safeguard Against Human Error
While human vigilance remains crucial, asset-intensive organizations can significantly reduce the risk of errors by leveraging advanced software solutions tailored for SAP environments. Solutions like those offered by S4A IT Solutions provide critical safeguards:
- Planning and Scheduling Optimization: Enhance efficiency and reduce human error by leveraging automation capabilities to optimize planning and scheduling processes. By streamlining task sequencing, resource allocation, and scheduling adjustments, organizations can ensure maintenance activities are executed on time while maintaining control over decision-making. Envoy Balance is one such solution that saves time and cuts down on human error by reducing manual effort and improving accuracy in planning and scheduling workflows.
- Real-Time Data Validation: Built-in validation checks help detect data inconsistencies at the point of entry, ensuring accurate information is recorded and preventing errors from propagating through the system.
- Mobility Solutions: Mobile-enabled tools allow technicians to access work orders, asset history, and data when offline in the field, reducing transcription errors and ensuring accurate information is captured at the asset source. Solutions, like BlueWorx, provide on-the-go access to critical information, empowering maintenance teams with full offline capability.
- Integrated Communication Tools: Seamlessly connecting field teams, supervisors, and planners ensures everyone operates with the same up-to-date information, reducing the risk of miscommunication. Envoy Tempus accomplishes this by simplifying and mobilizing time entry for your entire organization, coupled with push notification capabilities to your field technicians via BlueWorx.
- Logistics Management: Advanced logistics capabilities, such as those provided by Envoy Maestro, ensure spare parts and resources are available precisely when and where they are needed, reducing downtime caused by supply chain inefficiencies and last-minute scrambles.
- Intuitive User Interfaces: Simplifying SAP processes reduces the cognitive load on employees, minimizing the likelihood of errors during task execution.
Mitigating Errors, Maximizing Success
Reducing human error is not merely about avoiding disaster; it is a strategic investment in efficiency, safety, and profitability. Studies show that human error accounts for up to 70% of industrial accidents and is a leading cause of unplanned downtime.
Fortunately, organizations have the power to protect their operations through smart technology investments. Solutions – such as BlueWorx, Envoy Balance, Envoy Tempus, and Envoy Maestro – serve as a critical line of defense, helping organizations automate processes, enhance data accuracy, and ensure operational excellence.
Because when the margin for error is measured in millions of dollars, every safeguard counts. Reach out to S4A today to book a demo and see any one of our EAM and/or logistics solutions in action.
