Open Access
Table 5.
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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