What does it take to have Best in Class Maintenance?
Breaking down the findings from the Aberdeen research paper on Collaborative Maintenance Strategies yields some interesting results.
The paper reports on results from 300 surveys of organizations maintenance operations to determine which organizations have the best in class maintenance operations. The survey includes a healthy mix of small to large organizations, seniority or rank of respondents, geographic location, and industry represented.
What is meant by Best in Class Maintenance?
Best in Class maintenance organizations are those whose that fall in the top 20% for measures like
– Asset productivity (as a % of capacity)
– Asset uptime and Availability
– ROI on assets
– Maintenance Budget as a % of Revenue
What do they do differently?
i) Best in Class maintenance organizations are more likely to employ high-level maintenance strategies like Predictive Maintenance, RCM, or Root Cause Analysis.
ii) Putting a senior executive in charge of the maintenance operations, as opposed to silo-ing it away from production, logistics, and other areas of the organization. It lends more importance to what the maintenance department is trying to achieve, and gives them more resources to do it.
iii) Stressing the use of analytics: Asset performance data is tracked and analyzed over time and is systemically shared with related personnel.
iv) Employing software technologies to run maintenance department: Tied together with high-level analytics, CMMS/EAM programs are far likely to be deployed in Best-in-Class organizations that in it’s counterparts. This type of technology decision goes hand it hand with the other goals stated here – monitoring KPI’s, using Analytics, involving management and other stakeholders, and tying into PdM or RCM run equipment.
v) Establishing KPI’s that are updated often – weekly at a minimum, and are used to make adjustment to the maintenance strategy.
The main thing these companies do better isn’t the specific methods or technologies they employ – it’s their focus on maintenance as being an input to production, instead of an afterthought. This means freeing up more resources and spending more cash in the short term – for things like PdM devices, CMMS license and set up, and establishing analytics tools.