Not having a key piece of information can make a task frustrating and take much longer to complete. This is certainly the case when it comes to replacing pressure and temperature gauges.

With multiple changes in plant ownership and upgrades to processes over the years, finding the information you need to install the right gauge for the job can be nearly impossible. In most cases, the result is a mishmash of gauges – various sizes, ranges, connections, vendors, and so forth – which just creates more confusion along with increased failure rates and costs.

WIKA’s engineers have found that gauge inventory levels can be significantly reduced in most cases. In a few cases, a careful analysis of the gauge population made it possible to cover 95% of installations with just two gauge models.

Moreover, the numerous benefits of improving, standardizing, and consolidating the gauge population ripple throughout the plant.

Benefits of Streamlining Your Gauge Population

1. Streamlining your gauge population reduces inventory costs by as much as 30%

Gauge inventory typically mushrooms under a cloud of uncertainty. The purchasing department is often unsure about what to order, and maintenance is frequently providing a best guess, too.  As a result, shelves are stocked with unnecessary parts, which waste time and money.

During an instrument audit, WIKA engineers evaluate all gauge installations and review existing inventory. After analyzing this data, they provide recommendations that maximize field coverage, minimize the complexity of gauge configurations, and help eliminate redundant, obsolete inventory. An instrument audit can reduce inventory costs by as much as 30% in some cases.

2. Streamlining your population helps eliminate guesswork when replacing pressure and temperature gauges

When standardization and consolidation are introduced at a facility, the complexity of the gauge population is greatly reduced. This means locating and installing the right gauge becomes easier and faster. In fact, WIKA has found that maintenance time can decrease by as much as 25% after the gauge population has been streamlined.

Reducing the complexity of the gauge population is an integral part of a sustainable gauge maintenance process. Once standardized and consolidated, proper control measures, such as ERP setup and MOC documentation, help eliminate guesswork.

3.  Streamlining your gauge population gives more insight into proper inventory levels for gauges

If misapplied, a gauge will provide limited service life. For example, vibration is one of the most common reasons for gauge failure. If a local indicator is not engineered to withstand this tough operating condition, it will fail prematurely.

With the right gauge installed for the demands of your process, you can accurately predict the life of your gauges. Armed with this data, you’ll be able to adopt leaner inventory measures to further reduce your costs, and you’ll be dealing with fewer recurring failures.

Hit the Reset Button with an Instrument Audit

An instrument audit gives you the opportunity to make up for years of poor gauge maintenance and purchasing practices – even with limited engineering resources. WIKA’s Full Audit Service Team provides support from audit to implementation – all at no charge. We work together with your team to give you a complete picture of your gauge population along with improved specifications that lower your total cost of ownership.

Learn how much you could save after an audit with our new FAST Savings Calculator. Or if you have questions, you can speak with a FAST engineer at

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