Key factors versus maintenance performance at various levels.
|Key factors||Level 3 (100%) advanced||Level 2 (66.7%) intermediate||Level 1 (33.3%) reactive|
|Maintenance effectiveness||Maintenance performance is very satisfactory.||Maintenance program is effective but could still be improved.||Maintenance has significant room for improvement, or preventive maintenance program is lacking/reactive maintenance.|
|Maintenance strategy||Employ predictive maintenance (PdM) strategy for sustainable improvement. All problems are analyzed and permanently solved.||Use preventive maintenance (PM) as a main approach, usually age-based or cycle-based.||Rely heavily on reactive maintenance (RM), no equipment health information involved.|
|Task planning and scheduling||More than 90% of work that is planned is accomplished. Low overtime for maintenance activities (<15%).||More than 50% work planned accomplished. Relatively high overtime (>15%).||Less than 50% work planned accomplished. High overtime (>30%).|
|Profitability||Significant cost saving due to failure reduction and life extension.||Cost-effectiveness is satisfactory.||Not cost-effective.|
|Continuous improvement||Proactive maintenance. CBM or PHM applied, performance measurements are in place and effectively used.||Have PM in place with management involved in policy settings and reviews.||Have no CBM or PHM. Low involvement of management. Reactive maintenance is very common.|
|Maintenance training||Educational plans for each maintenance worker. A global R&D team that is responsible for developing and implementing prognostic and diagnostic techniques.||Skilled staff normally qualified on a few machines. Small team that is responsible for developing and implementing prognostic and diagnostic techniques.||No training on how to use PM or other maintenance strategies. Lack of system to collect maintenance knowledge. No team that is responsible for developing and implementing prognostic and diagnostic techniques.|
|Total productive performance (TPM)||Overall Equipment Effectiveness (OEE) is greater than 80%.||Overall Equipment Effectiveness (OEE) is between 50% and 80%.||Overall Equipment Effectiveness (OEE) is less than 50%.|
|Organizational readiness||Leadership involvement R&D support.||Lack of sufficient R&D support & leadership involvement.||“Fire Fighting” approach.|
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