What is the Reliability Paradox in manufacturing?
The Reliability Paradox is an operational state where a factory achieves high temporary OEE scores through frequent, short-term reactive repairs, while the underlying mechanical integrity of the assets deteriorates, leading to an inevitable and catastrophic failure.
For Paula (the Strategic Leader), the paradox is a financial liability.
It creates a "Mirage of Efficiency" that prevents the shift toward high-impact Reliability-Centered Maintenance (RCM).
Fabrico eliminates this blindness by providing Mike (the Tactical Manager) with a real-time view of both production pulses and technical failure trends.
Lever 1: Master MTBF to Identify "Bad Actor" Assets
What is Mean Time Between Failures (MTBF) in OEE?
MTBF measures the average time a machine operates between unplanned stops; it is the ultimate indicator of process stability and the most effective way to identify the 20% of assets causing 80% of your production risk.
In high-speed Food & Beverage or Plastics lines, a machine that stops every 30 minutes for a "quick fix" might still show decent OEE Availability.
However, its MTBF is dangerously low, indicating a chronic mechanical issue that manual logs often miss.
Fabrico’s integrated OEE and CMMS identifies these "Bad Actors" automatically, triggering Condition-Directed Tasks before a minor hiccup becomes a total line stoppage.
Lever 2: Slashing MTTR with Field-Ready Mobile Execution
What is Mean Time to Repair (MTTR)?
MTTR is the average time taken to troubleshoot and repair a failed asset, including the time spent on notification, diagnosis, and actual labor; reducing MTTR is the fastest way to reclaim "lost" OEE availability points.
The most expensive part of a repair isn't the wrench turn; it is the Decision Latency.
In siloed factories, technicians waste 30% of their day walking back to offices to find manuals or parts.
Fabrico’s Field-Ready CMMS puts the "Cure" in the technician's pocket.
By scanning a machine’s QR Code, Tom (the Lead Technician) accesses the OEE history and digital SOPs instantly, ensuring the "Fault-to-Fix" cycle is optimized for maximum uptime.
Comparison Matrix: OEE Monitoring vs. System of Action
| Strategic Metric |
Standalone OEE (Vorne/Evocon) |
Manual Excel Logs |
Fabrico (System of Action) |
| Fault Discovery |
PLC Signal (Data Only) |
Operator Observation |
Hybrid (PLC + Vision) |
| Response Trigger |
Visual Alert |
Verbal Request |
Automated Mobile WO |
| MTBF Tracking |
Historical Only |
Subjective / Poor |
Real-Time Predictive |
| MTTR Reduction |
Minimal Impact |
Negative |
High (Field-Ready App) |
| Root Cause Depth |
Guesswork |
Tribal Knowledge |
Visual (Zoom-In) Proof |
| Decision Latency |
Moderate |
Very High |
Zero (Automated) |
The Financial Blueprint: Lowering the Maintenance Cost per Unit
For Paula, the business case for a System of Action is built on "Capacity Reclamation."
By stabilizing MTBF through integrated action, she can reduce the volume of expensive emergency parts and overtime labor.
This directly lowers the Maintenance Cost per Unit and ensures that her global fleet reaches its full residual value.
As the system builds 12 months of clean 3D data, it creates the essential foundation for future AI-driven optimizations on the roadmap.
Stop managing the scorecard. Start engineering your reliability with a System of Action.
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