Ways to Measure Your

Preventive Maintenance Program

Maturity Matrix
Elements LEVEL
LEVEL 11 LEVEL
LEVEL 22 LEVEL 3 LEVEL
LEVEL 44 LEVEL
LEVEL 55
NOT
NOT ENGAGED
ENGAGED EXPERIMENTING
EXPERIMENTING ENLIGHTENED GOOD
GOOD PRACTICE
PRACTICE BEST
BEST PRACTICE
PRACTICE

Process Maps developed

Process Maps developed Process Maps developed Process Maps developed
PM Workflow Process for 100% of the Proactive
No Process Maps exist for 20% of the Proactive for 50% of the Proactive for 80% of the Proactive
Maps Workflow Model with RACI
Workflow Model Workflow Model Workflow Model
charts and step descriptions

Database meets and

20% of assets completed to 50% of assets completed to 100% of assets completed to exceeds ISO 14224 and
Equipment Catalog Does not meet any standard
standard standard standard validated by an outside
organization

Informal Criticality Formal Criticality Good granularity, could Good granularity, could
No formal Criticality
Criticality Assessment Assessment performed (little Assessment performed be used to identify asset be used to identify asset
Assessment performed
or no granularity) (good granularity) coverage and work priority coverage and work priority

PM Evaluation performed on
No PMs are based on MTBF trending upward on top 10% of assets and PMs Enable Proactive Workflow Prevention of failure is the
Expectations
Failure Modes 60% of equipment developed based on Failure Model #1 goal
Modes

A full-time lubricator (Best

PM MATURITY ELEMENTS

Employee Level I certification with

Maint Tech) has been Level II certification with Certifications plus task
Certifications and Nothing formal written practices - MTBF of
identified and has started written practices qualification
Qualifications lubricated equipment begins
training

Some basic database Standards created with Advanced standards created

Standards and None found, Lube Program
Nothing formal standards created with controls to monitor, formal and MOC process used for
Controls has standards and controls
controlled input workflows exist changes

Alarms present, both

No operator alarms are used Alarms present, but are Alarms present, both
Alarming Methods Nothing formal standard and statistical, with
to identify failure modes generic or overall alarms standard and statistical
review process

Missed Opportunity / RCA only when prompted, RCA only required on high RCA activity based on good RCA on failures of all
Limited and informal RCA
Investment informal in nature profile failures triggers (e.g. Criticality) monitored equipment

Task Qualification for all

Operator Checks are in place Repeatable PMs are written Effective PM Procedures are personnel who perform PM,
None found with steps,
PM Procedures -coordination and response based on specific failure written based specific failure operators and maintainers
standards, and specifications
successful modes on top 10% of assets modes on 50% of assets - 100% coverage of critical
assets

Technology PDAs for Operator Rounds PDAs for Maintenance

None Operator Checks developed Fully integrated (database)
Integration implemented personnel implemented

Some buy-in on Operator Good integration, reviewing Fully integrated, operations

Operations Some buy-in, looking at PM
None Checks but not totally Asset Health, understand accountable for reliability
Involvement metrics but not utilizing
successful importance efforts

FRACAS in place to modify

PM Compliance using Cannot measure - PM More than 20% of PMs are More than 50% of PMs are 100% of PMs are measured
PMs based on this reporting
10% Rule Program is not functional measured to standard measured to standard to standard
process

All PM findings generate

No PM work orders
Work Order Creation created, informal rounds are
established
PM Procedure standard
Most PM findings generate All PM findings generate work orders and are
developed and implemented
work orders work orders reviewed for proper close out
on 5% of assets
100%

Planning and Planner/Schedulers in Planner/Schedulers are Planner/Schedulers planning

Nothing formal Planning/Scheduling at 100%
Scheduling position training and Task Qualified and scheduling 40% of work

Metrics / Justification
Tracking Availability, EM vs. 10% Rules of PM applied Track lagging and leading
Possibly tracking production
Nothing formal PM Labor Hours (lagging to top 20% of assets (most indicators and take corrective
outputs or PM Compliance
indicators) critical) actions

Dedicated personnel are Maintenance personnel who Dedicated resources, multi-

Maintenance Techs inspect
Resource Allocation None dedicated to PM; all PMs perform PM are task qualified discipline trained to increase
and repair equipment
have written instructions to execute to standard effectiveness

All equipment failure modes Completed to established

Requalification / Spot check based on Quantitative and qualitative
None have been identified with criteria (e.g. all equipment in
Commissioning request procedures in place
maintenance strategy applied PdM Program)

Continued on back...

North America • Europe • Latin America • Middle East • Asia-Pacific

World Headquarters GPAllied EMEA
4200 Faber Place Drive Guldensporenpark 21-Blok C
Charleston, SC 29405 B-9820 Merelbeke, Belgium
o. 888.335.8276 o. +32(0)9.210.17.20
f. 843.414.5779 f. +32(0)9.210.17.28
www.gpallied.com
 Ways to Measure Your
Preventive Maintenance Program
Maturity Matrix
Elements LEVEL
LEVEL 11 LEVEL
LEVEL 22 LEVEL 3 LEVEL
LEVEL 44 LEVEL
LEVEL 55
NOT
NOT ENGAGED
ENGAGED EXPERIMENTING
EXPERIMENTING ENLIGHTENED GOOD
GOOD PRACTICE
PRACTICE BEST
BEST PRACTICE
PRACTICE

Some PM tasks are

No PM tasks are mapped to
the prevention or detection
Failure Mode Driven of a specific failure mode;
OEM recommendations are
followed with no analysis
A few PM tasks are mapped
mapped to the prevention
to the prevention or detection Most PM tasks are mapped All PM tasks are mapped to
or detection of a specific
of a specific failure mode; to the prevention or detection the prevention or detection of
failure mode; some OEM
most OEM recommendations of a specific failure mode a specific failure mode
recommendations are
are followed
followed

PMs completed within the

PREVENTIVE MAINTENANCE PROCEDURES

PM scheduling occurs +/- PM scheduling occurs +/- PM scheduling occurs

PMs worked into the
Scheduling Discipline
schedule where possible
month they are scheduled;
20% of scheduled time and 10% of scheduled time and +10%/-0% of scheduled time
completed within +/-40% of
frequency frequency and frequency
allotted time

Most PM procedures have All PM procedures have

Feedback Mechanism
Some PM procedures crafts' feedback when crafts' feedback when
A few PM procedures have
have crafts' feedback when returned; most feedback returned; all feedback is
No feedback from crafts crafts' feedback when
returned; critical feedback is is processed by Planner; processed by Planner;
returned
processed by Planner feedback process is feedback process is
formalized formalized

Most PM procedures have Most PM procedures have All PM procedures have

PM details left to the
Some PM procedures have detailed tasks and steps, detailed tasks, steps, and detailed tasks, steps, and
Repeatability interpretation/skill of the
detailed task and steps some have instructions instructions to ensure instructions to ensure
craftsperson
where needed repeatability repeatability

Most PM tasks are All PM tasks are quantitative

Most PM tasks are
Most PM tasks require at quantitative with detailed with detailed maximum
Quantitative Some are quantitative, most quantitative with detailed
least one measurement of maximum and minimum and minimum values and
Inspections are not maximum and minimum
some kind values and action items action items when limits are
values
when limits are reached reached

ROI Unknown - Probability "0" Minimal to no ROI 4:1 8:1 16:1

% Failure
>70% >50% <40% <25% <10%
Maintenance

>65% Overall >80% Overall

PM/PdM Balance 100% / None 95% / 5% 85% / 15% 25% PdM 50% PdM
40% PM 30% PM

Exists on critical assets Exists on all assets Exists on all assets

Asset Health Not measured Not measured
RESULTS / SCORECARDS

>65% Green" >75% Green >90% Green

Route Adherence Not measured <50% >70% >85% >90%

% Lube and PM
Recommendations <15% <30% >50% >75% >90%
Implemented

MTBF - Mean Time Experimenting on 10% of Exists on critical assets Exists on all assets -
Not measured Exists on all assets
Between Failure critical assets >40% FRACAS applied

PM Compliance using
Not measured 10% >50% >85% >90%
the 10% Rule

% PM
Recommendations <15% <30% >50% >75% >90%
Implemented

North America • Europe • Latin America • Middle East • Asia-Pacific

World Headquarters GPAllied EMEA
4200 Faber Place Drive Guldensporenpark 21-Blok C
Charleston, SC 29405 B-9820 Merelbeke, Belgium
o. 888.335.8276 o. +32(0)9.210.17.20
f. 843.414.5779 f. +32(0)9.210.17.28
www.gpallied.com