Reliability Audits
Customer Profit Reinforcement® is the methodology Adams developed in the 1990s and has refined across more than 600 customer engagements since. The principle is simple: every plant has dollars leaking out — through compressed-air losses, oversized cylinders, undersized lines, the wrong valve in the wrong duty, regulators set conservatively because nobody's checked them in eight years. We document those leaks, we rank them by ease and ROI, and we tell you which ones are worth chasing first. We don't sell you the audit; we sell you the savings the audit finds.
The scope, plainly stated.
- 012-day on-site walkdown by two senior application engineers
- 02Ultrasonic compressed-air leak survey, geo-tagged on a plant floor map
- 03Hydraulic system pressure-drop and oil-condition diagnostics
- 04Valve duty-cycle review on critical pneumatic loads
- 05Reliability data review: failure history, downtime logs, MTBF curves
- 06Ranked opportunities list: dollars-per-year, install effort, ROI months
- 07Implementation proposal — phased by ROI tier, not all-at-once
- 08Follow-up resurvey 90 days after phase one to verify the savings
The methodology applied to this service.
Same principle on every engagement. Walk first, document second, rank third, implement fourth. The service determines what we’re looking for, not how we look.
- 01step
Walk the floor
Two engineers, two days, on-site. We instrument what needs instrumenting. We talk to the millwrights and the operators, not just management. We don't bring a sales team.
- 02step
Document opportunities
Every finding is geo-tagged to a plant map, photographed, and cost-quantified. The deliverable is a structured opportunities list, not a 60-page narrative report nobody reads.
- 03step
Rank by ease and ROI
Each opportunity gets a $-per-year, an install-effort score, and an ROI-months estimate. The ranked list lets your team decide what to chase first. No pressure to do everything.
- 04step
Implement and measure
Phase one is usually low-effort, high-ROI items — leak patches, regulator resets, undersized lines. We resurvey after 90 days and verify the savings hit the meter. If they didn't, we keep working until they do.
Where this service has actually run.
$120k/yr in compressed-air savings
Plant engineering had been running the rotary-screw compressor house at 98% load for the better part of two years. The reliability team was watching loaded-hour curves climb, two of the four 200 hp units were lined up for top-end overhauls, and the capital request for a fifth compressor was already drafted at $340,000 plus install.
10× longer valve life on a citrus juicing line
The customer was burning through poppet-style solenoid valves on the FMC extractor finishers at an alarming clip — average mean time between failures of 38 days, sometimes as little as 26 days during peak season. Each failure took the affected extractor offline for 90 minutes, and during November–April that meant losing roughly 4,200 gallons of juice per incident at peak rates.
Questions we hear most
Have a problem on a line right now?
Tell us where it hurts. A senior application engineer will respond within one business day — same-day for true downtime emergencies.