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Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Mr. Vega,
All good questions. I would suggest adding tracking of training hours and come up with a system to measure results of the training. In today's world this is sorely needed.  Before and after aptitude tests would be a way to measure effectiveness of training. Many would probably resist the testing, however this is a way to instantly measure the effect of the training.  The trainees need to realize that the testing is not about them it is more about measuring the overall success of the training.  It could be that the training is not presented as efficiently as it could be.  I visualize an operation where there is cross training for operations and maintenance personnel. This would help in communications between the two departments.
Thanks,
Alfred DeVaux, CMRP, CRL
Trainer for Precision Maintenance

------------------------------
Alfred Devaux
Reliability Engineer
Saint Francisville LA
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Daniel,

These kind of assessments are a large part of our day-to-day.  We have our own gap analysis developed and I'm sure many with us here.  Here are a few pointers from our perspective that may help:

1.  Execution is very important to assess.  Documentation-data-and KPI's are important but 100% useless unless you have good execution
2.  Focus on key maintenance processes, they are:  A, Preventive Maintenance (including inspections)  B.  Work Management daily/ weekly and Shuts.  C.  Materials Management  D.  Root cause.   E.  Craft skills. There are a lot more to maintenance, but these are the most important

How to assess execution:  For example, attend morning meeting where jobs are handed out. Ask a few guys if they mind if you go over their work orders.  If yes, ask if you can also check how the jobs are going, so at 11:00 you find them in the field and check if they have the parts, the tools, how the LoTo went etc.  Cheeck skills by asking how they are doing the alignment, tightening of bolts, etc, etc.

At the end of the day, effective maintenance comes down to:

1.  Execute job faster, safely with high quality
2.  Prevent problems

That's it.  All other things are just supporting factors to accomplish THAT.  Leadership, CMMS, standard documents, planning, scheduling, everything..... supports those two goals that will both lead to reliability (higher OEE) and lower cost.





------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

I think Torbjorn Idhammar summarises it all.  The actual execution of all the plans and schedule is where the real effectiveness can be monitored; the rest all aspects are only supporting stuff

------------------------------
Shabir Khan
Mari Petroleum Company Limited
Dharki
------------------------------

Original Message:
Sent: 06-18-2021 02:31 PM
From: Torbjorn Idhammar
Subject: Maintenance Effectiveness Audit (MEA's)

Daniel,

These kind of assessments are a large part of our day-to-day.  We have our own gap analysis developed and I'm sure many with us here.  Here are a few pointers from our perspective that may help:

1.  Execution is very important to assess.  Documentation-data-and KPI's are important but 100% useless unless you have good execution
2.  Focus on key maintenance processes, they are:  A, Preventive Maintenance (including inspections)  B.  Work Management daily/ weekly and Shuts.  C.  Materials Management  D.  Root cause.   E.  Craft skills. There are a lot more to maintenance, but these are the most important

How to assess execution:  For example, attend morning meeting where jobs are handed out. Ask a few guys if they mind if you go over their work orders.  If yes, ask if you can also check how the jobs are going, so at 11:00 you find them in the field and check if they have the parts, the tools, how the LoTo went etc.  Cheeck skills by asking how they are doing the alignment, tightening of bolts, etc, etc.

At the end of the day, effective maintenance comes down to:

1.  Execute job faster, safely with high quality
2.  Prevent problems

That's it.  All other things are just supporting factors to accomplish THAT.  Leadership, CMMS, standard documents, planning, scheduling, everything..... supports those two goals that will both lead to reliability (higher OEE) and lower cost.





------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

These are all tools to accomplish maintenance tasks, as Torbjorn says, faster, cheaper, safer.

I’d think a measure of effectiveness would come from the business/operations side…our customer.

Can the department predict the budget required to deliver the standard of service their sponsor expects? Can they execute it reliably?



---------------------------------
Karl Burnett

Solvay, Inc
Anderson SC
---------------------------------



Original Message:
Sent: 06-18-2021
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Daniel:
1. Production plays a key role in how effective maintenance is performing.
2. The equipment health is reflective of how effective maintenance is being performed.

The items Torbjorn mentioned must be in place in order to evaluate an effective maintenance department.  If production processes are not in place and ran effectively it will be reflective in maintenance.  Even if you have all the tools in place if production is not supportive and assisting in the maintenance process, the maintenance program will not be effective or efficient.

------------------------------
Wayne Offermann
Maintenance Manager
Lawrenceville GA
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Daniel, 

I think another effective measure of reliability and maintenance effectiveness is looking at the number of PM tasks that require rework or man-hours spent performing reworks after PM tasks. This will speak to the skill level of the Maintenance Department and effectiveness of planning. If the work is done correctively, more work is not required to correct errors made performing "routine" maintenance. 

Good luck with the evaluation and please share what you come up with and how it went.

Respectfully,

------------------------------
Robert Winters
Sr. Predictive Maintenance Engineer
Associated Electric Cooperative, Inc
Marston MO
+1 (573) 643-6203
rwinters@aeci.org
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Hi Mr. Daniel 

 Really the subject was toughed me and forced me to share what we are facing in our company to get improvement the maintenance, in below just two barrier what are facing so far     

1- Within good maintenance policy and good maintenance procedure must be all management respecting and support all policy and accept the maintenance department and their activities and it is not look like evil from any side from time must be enough for maintenance without any effect in the operation and cost as well which allocating to carry maintenance activities must be equal to it 
2- Must be all maintenance tools and equipment which are required for maintenance activities are available and in hand

------------------------------
Ahmed M.Iesa BEng
Maintenance Engineer
Jubail
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Hi Daniel,

I think that is a great list. Just note that formalized processes themselves, whether they be SOP's or workflow diagrams need to be revisited periodically. You're really also getting into the aspects of ISO-55000 for asset management, specifically an asset management system in Para 4.4 of ISO-55001. So the question is how well is knowledge and information maintained and updated?

------------------------------
John Helwig
Asset Management Consultant
CDM Smith
Kensington MD
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Wow, lots of good information in the responses to this question! I was looking for something similar to the items you identified and came across a maturity matrix for planning and scheduling created by Allied Reliability. It is organized and well put together, something like this may help guide you to your answer. The difference is, it ties processes to the maturity of the organization. As the organization gains the skills and experience to support and implement more advanced processes this should drive reliability. It can be a valuable reference to get a baseline for maturity of a maintenance department/organization. However, all of the processes in the world are meaningless if they are not managed and effective.

Maintenance effectiveness and something like established processes and organizational maturity are different things.  I think they are related and one could be used as a leading indicator to the other but they are different.

The question is how do you measure all of the items pointed out in the initial post? More analysis needs to be done whatever you determine to track as to the effectiveness of the item. For example, the question - Is there a formalized process to ensure the updating of equipment information? leads to the questions is this complete with a RACI chart and is it tracked? If not followed what are the repercussions? If it is followed are there rewards? Does Leadership in the maintenance organization sponsor and support the importance of the processes? Who manages/owns the process? My point is, because a process exists, that does not mean it has any value if folks don't adhere to it. Even if the policy is adhered to is it value added?  This leads to change management and the importance of ensuring when a new process is implemented there is a plan to manage its sustainability.

I'll refer to the good old saying, you can't manage what you don't track. Processes are great to have but there needs to be a level of monitoring and control that verifies process effectiveness and follow up for continuous improvement when opportunities are identified.  

There are tons of metrics one could identify to track for Maintenance effectiveness. How granular do you want to go? Below are some high level ideas that might get your gears turning -

Planning

• Planned vs Actual
  • This impacts scheduling efficiency

Scheduling

• Scheduling efficiency
  • Is the schedule properly loaded for available resources?
  • Is the Schedule locked 1 week ahead of time and bought into by stakeholders?
  • Equipment will be available and all parts/materials are available to complete the job
  • Is the backlog of work managed with an accurate list of ready to work jobs that can be scheduled?

Execution

• Does the work start and complete as scheduled?
  • Impacted by the plan accuracy, ongoing work and scope change, break in work consuming resources

Maintenance Costs and hours for -

• Corrective work
• PM work

Emergency Work

• Emergency Work orders
• Any work orders that break the weekly schedule
  • Are we not doing the right PMs?

Equipment/Mechanical Availability

• Reliability metric
  • In theory if you are executing the right PMs, reliability will be directly related
  • More PM hours should decrease corrective maintenance hours (again, doing the right things, value added activities)

Safety

• Injuries and severity levels – safety and reliability are proven to be directly related
• Good catch program
• Near Miss documentation/follow up

Environmental

• Incidents and exceedances by severity level – community impact
• Your maintenance effectiveness won't matter if the facility cannot operate within environmental compliance

Inventory

• Stock outs
• Supply Chain Management needs to be reliable and effective to support maintenance activities

 

I also love the reference to ISO55000 by John Helwig. So much good information and direction in ISO55000!

------------------------------
Jason Weis PMP CMRP CRL
Project Manager
Trainer, Pennsylvania
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------

Hi Daniel

You might find the Energy Institute's "Capability maturity model for maintenance management" a useful reference. 

https://publishing.energyinst.org/topics/asset-integrity/capability-maturity-model-for-maintenance-management

Another relevant reference is from the HSE (UK) "Maintenance System Assessment: Guidance Document".   

https://www.hse.gov.uk/research/rrpdf/rr237.pdf

There is also "Maintenance Management Auditing" by Anthony Kelly. 

Best regards
Michalis
​

------------------------------
Michalis Hadjiandreou
Manufacturing Reliability Engineer
Edinburgh
------------------------------

Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
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Hello Daniel, Below are some docs, you may find helpful. Thanks

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Usman Umar
Toronto ON
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Original Message:
Sent: 06-18-2021 10:38 AM
From: Daniel Vega
Subject: Maintenance Effectiveness Audit (MEA's)

Hi Folks. I'd like to know if any forum participants has a document they could share/upload that can help me determine the maintenance effectiveness of a maintenance department. I am specifically interested in a PHASE 0, 1 or 2 (establishing a whether the department is at the beginner, infant or toddler stages of maintenance effectiveness). If there are none available, what 20-25 questions would one ask to grade a maintenance department's effectiveness (below or above toddler (phase 0-1-2))? These are the initial questions I came up with:

1 - Is/Are there a Plant Maintenance Policy/Policies available?
2 - Does the Mx Dept. have a strategy that defines the organization of their Maintenance Methods and their missions?
3 - Is there an Equipment Criticality Matrix?
4 - Has a level of criticality for each equipment been set (e.g. Critical / Essential / Non-Essential)?
5 - Is there a maintenance library or technical resource center that employees can access in house?
6 - Is there a formalized process to ensure the updating of equipment information?
7 - Is there any indication that the maintenance department is practicing 5S?
8 - Is there any indication of safe LOTO practices (i.e.. LOTO board, communications board,…)? Is LOTO followed and is it an essential part of each task?
9 - Is there a formal registration system for maintenance data? It can be a CMMS or any other WO recording and or tracking system.
10 - Is there a skills management system?
11 - Is there a formal system to upload/analyze equipment failures?
12 - Is there a Production and Maintenance planning session to allow maintenance plans to take place within production restraints?
13 - Does the department have KPI's for each section/area of the department?
14 - Is there a formalized method/system for measuring technological advances and its uses? (i.e.. predictive technologies advances; computer/programming advances; etc.)

IYO - What else could be initially important to know?

------------------------------
Daniel Vega
Reliability Manager - PDM Techologies
Hope Mills NC
------------------------------