Comparative Behavioral Analysis of Expert and Novice Inspectors in Equipment Patrol Inspections

In the maintenance domain, significant progress has been achieved through the integration of emerging technologies. In this study, we focused on industrial inspection processes, recognizing them as the core maintenance operations. Current technological solutions often rely heavily on models and data specific to the target facilities, often disregarding the critical role of human inspectors. In this study, ws aimed to extract strategic inspection knowledge from expert and novice inspectors in industrial inspections. A field study was conducted at an oil refinery in Japan, focusing on patrol inspections of plant equipment. Three expert inspectors (15-37 years of experience) and three novice inspectors (1-2 years of experience) performed inspections according to standard protocols, including predefined device lists and patrol routes. The results showed that the expert inspectors identified significantly more inspection points and demonstrated flexible inspection strategies based on device mechanisms and risk assessment, whereas the novice inspectors adhered closely to the prescribed procedures. In addition, the expert inspectors dynamically adjusted the inspection depth and focus according to equipment conditions and potential failure risks. These differences indicated that the performance of expert inspectors was driven by the integration of experience-based reasoning and situational judgment. Furthermore, the field study revealed variability in the inspection approaches, which enhanced the overall assessment of the plant by incorporating diverse perspectives. These findings provide concrete insights into the strategic knowledge underlying effective patrol inspections and offer implications for improving inspection training and knowledge transfer.