Overall Result.

61%

Maintenance Reality Check Company name and date of assessment

Modify grid text to suit your Business Company XYZ Jan-09 by: John

Category Legend: Excellent Good Requires focus

Management Management values 80% Management has 100% Management vision is 100% Vision is 100% Management has good 100% Plant maintenance 100% Plant maintenance 100% Management team has 100% The maintenance 100% Maintenance is 100% 98%
Support and of the maintenance culture of continuous communicated to staff communicated to understanding of the objectives are goals are published received maintenance function is viewed as viewed as an intergral
Culture function improvement entire plant team maintenance function understood and and posted for all to management training part of the profit plan part of manufacturing
and purpose communicated see and exposure not as a cost center

Organization A clear command and 60% Work request method 70% Supervisor floor to office 100% Supervisor to 60% Job descriptions and 70% Organization charts are 60% Existing maintenance 90% Current maintenance 60% Production 60% Organizational 60% 70%
control structure is in reviewed and time adequate technician ratios requirements exist for posted and up to date on organizational staff levels appropriate management has a structure is reviewed
place for the communicated adequate entire maintenance staff, facility information boards structure appropriate for production facility clear understanding of and adjusted on
maintenance team management and for production facility the maintenance yearly basis
technicians organization

CMMS Computerized 60% CMMS asset heirarchy 60% Notification and work 60% Work order flow is 40% Work orders are raised 60% Estimated hours placed 30% Work orders are coded 60% Completed work orders 90% Employee information 100% Stores inventory / 60% 62%
Maintenance is fully and adequately order writing training is documented and for all work, including on all incoming work correctly when are timely and properly is stored in the CMMS procurement process
Management System developed. conducted for all communicated to all breakdowns orders planned and completed and closed link with CMMS
(CMMS) exists maintenance and relevant Maint and scheduled by supervisor/Planner
operations employees Ops personnel

PM / PdM Value of Preventive 60% PM techniques are 20% Basic PM inspection 10% Frequency of 30% Maintenance procedures 20% Detailed PM checklists 60% Operators inspections 40% Predictive Maintenance 50% PdM in place for all 40% PM and PdM 100% 37%
Maintenance program developed and stored tasks are established inspections is based are regularly reviewed. are in place for each are part of the PM (PdM) techniques are critical equipment programs are audited
is understood and within task lists for all critical equipment on measured failure piece of equipment program understood and valued on regular basis
supported by all rates by all.

Maintenance A work management 60% Planning function 60% Planner position exists 60% Planner to technician 60% Backlog work orders 60% Work orders have basic 60% Work orders have 60% Weekly work schedule is 60% Maintenance 60% All scheduled work is 60% 60%
Planning, process is in place, exists ratios adequate. have man-hour estimate planning detailed plan developed engineering function planned and kitted
Scheduling and documented and Greater than 10 to 1 exists
followed required
Supervision

Production and Work identification / 60% Work approval process 40% Production and 60% Production and 60% Daily work schedule is 60% Maintenance is 60% Long range 60% Production monitor all 60% Operations and 80% Process improvement 60% 60%
Maintenance service request in place maintenance Maintenace have co- coordinated between scheduled weekly. maintenance losses, not just Maintenace work as a and problem solving
process responsibilities are clear ownership of PM maintenance and forecasting exists maintenance downtime. team. (Priorities, goals, is approached as
process production. issues) team

Training / Safety, regulatory 60% Technical skill 60% A technical skill training 60% OEM training occurs 20% Problem solving 40% Maintenance 30% Maintenance 90% Operators are trained to 60% 1% of all maintenance 60% 3% of all maintenance 60% 53%
Development training register exists deficiencies are curriculum exixts and is for installed plant methods training is in management training management training perform minor man-hours are man-hours are
and is regularly understood and followed place completed for all completed by relevant maintenance, engaged in training engaged in training
reviewed actions in place to maintenance employees. operations and adjustments, lubrication,
address this. management etc.
personnel

Key Planning backlog of 40% Labor utilisation split 40% Mean time between 50% PM compliance to 60% All work complaince to 50% Work requests by priority 60% Downtime and 60% Overtime analysis 60% Breakdown work 60% Auditing of 60% 53%
Performance work measured understood and failures measured. schedule measured schedule measured are measured emergency analysis- requests measured miantenace
Indicators measured. E.g. Pareto charts are in management
Planned, place. processes occurs
preventitive,predictive,
corrective.

Procurement Purchasing controls 60% Inventory controls 70% Critical spares identified 60% Evaluate free issue 60% Stores performance 60% Enhance use of 60% Integrate planning 40% Establish purchase 60% Optimize inventory 60% Parts delivery and 60% 59%
and Inventory reviewed-authority reviewed and stocked and controlled issue indicators established consignment options function with stores - order and work order based on history and pick-up
management and responsibilities options and trended kit parts link within CMMS trends

Overall result Overall result 61%

 Company XYZ Jan-09
Maintenace Maturity Grid

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%
Management Organization CMMS PM / PdM Maintenance Production Training / Key Procurement Overall
Support and Planning, and Developmen Performance and result
Culture Scheduling Maintenance t Indicators Inventory
and management
Supervision
 Maintenance maturity Grid

Management Support and Culture

Overall result Organization
100%

Procurement and Inventory management 50% CMMS

0%
Key Performance Indicators PM / PdM

Training / Development Maintenance Planning, Scheduling and Supervision

Production and Maintenance