MAINTENANCE

ENGINEERING AND
MANAGEMENT
Chapter 1: Maintenance Organization

Mohd Azizee bin Sukor

Department of Mechanical Engineering
Politeknik Banting, Selangor
COURSE LEARNING OUTCOMES (CLO):

 Upon completion of this course, students should be able to:

 CLO1 : apply the concepts of maintenance organization and strategies to solve
related problems. (C3, PLO1)
 CLO2 : analyze the principles of maintenance strategies and elaborate on the
significance of a system approach to maintenance. (C4, PLO7)
 CLO3 : organize project management and finance by group in actual workplace
related to maintenance management. (A3, PLO11)
MAINTENANCE ORGANIZATION

1.1 APPLY THE ROLE OF MAINTENANCE MANAGEMENT

What is Maintenance?

 Maintenance refers to the activities performed to keep equipment, systems, or

facilities in a desired condition or state of repair to ensure they function as
intended.
 Maintenance includes both corrective and preventive activities to address failures,
breakdowns, or deterioration over time.
 Examples of maintenance activities include inspections, lubrication, repairs,
replacement, and cleaning.
What is Maintenance Engineering?

 Maintenance Engineering is the discipline that applies engineering concepts,

principles, and techniques to develop and improve maintenance strategies and
practices.
 Maintenance Engineers are responsible for analyzing maintenance data, identifying
problems, developing solutions, and optimizing maintenance processes to improve
equipment reliability, availability, and safety.
 Maintenance Engineering includes a wide range of technical areas such as
equipment design, condition monitoring, reliability engineering, and asset
management.
What is Maintenance Management?

 Maintenance Management is the process of planning, organizing, directing, and

controlling maintenance activities to achieve organizational objectives.
 Maintenance Management involves the coordination of resources, including
personnel, materials, and equipment, to ensure that maintenance activities are
carried out efficiently and effectively.
 Maintenance Management includes tasks such as developing maintenance plans,
scheduling maintenance activities, managing maintenance budgets, and monitoring
maintenance performance.
 Effective Maintenance Management can help organizations reduce downtime, extend
equipment life, increase safety, and improve overall operational performance.
1.1.1OBJECTIVES AND BENEFITS OF
MAINTENANCE MANAGEMENT.
Objectives of Maintenance Management:

 Ensure reliable and efficient operation of  Control maintenance costs and optimize
equipment and systems maintenance resources
 Reduce downtime and increase  Comply with regulations and standards
availability of equipment and systems in the industry
 Extend the lifespan of equipment and  Improve the quality of products and
systems services
 Maintain safety and reduce accidents in  Increase customer satisfaction by
the workplace ensuring timely and reliable delivery of
products and services
Benefits of Maintenance Management:

 Increased equipment and system  Increased efficiency and productivity

availability and reliability
 Improved quality of products and
 Reduced downtime and maintenance services
costs
 Enhanced customer satisfaction and
 Extended lifespan of equipment and loyalty
systems
 Increased profitability through better
 Improved safety in the workplace asset utilization and reduced
maintenance costs
 Compliance with regulations and
standards in the industry  Better decision-making through the use
of maintenance data and analysis
Real World Examples

Objective: To ensure the reliable and efficient operation of equipment and systems.
Example: A manufacturing company implements a preventive maintenance program for
its machinery to minimize unexpected breakdowns, reduce downtime and optimize the
utilization of their equipment.
Objective: To reduce downtime and increase availability of equipment and systems.
Example: An airline company schedules regular maintenance checks on its planes to
ensure they are safe and operational, minimizing delays and cancellations.
Real World Examples

 Benefit: Increased equipment and system availability and reliability.

 Example: A power plant's regular maintenance program minimizes unplanned downtime of its
equipment, ensuring a continuous supply of electricity to its customers.
 Benefit: Improved safety in the workplace.
 Example: A chemical plant implements a safety-focused maintenance program to minimize risks of
accidents, such as equipment failures or leaks, thereby reducing the chances of injuries to workers.
 Benefit: Increased profitability through better asset utilization and reduced maintenance costs.
 Example: A trucking company implements a maintenance program that minimizes repair and
replacement costs by conducting regular inspections and preventive maintenance, leading to higher
profitability through better asset utilization.
 Benefit: Better decision-making through the use of maintenance data and analysis.
 Example: An oil and gas company uses maintenance data analysis to identify patterns and predict
equipment failures, enabling them to schedule maintenance activities and optimize equipment usage
to minimize downtime and maintenance costs.
Objectives and Benefits Differences in Maintenance
Management:

Objectives: Benefits:
 Objectives refer to specific goals that  Benefits are the positive outcomes or
maintenance management aims to results that maintenance management
achieve. achieves when it successfully achieves
its objectives.
 Objectives may include improving
equipment efficiency, reducing downtime  Benefits may include increased
and maintenance costs, and increasing availability and reliability of equipment,
safety in the workplace. improved quality of products and
services, and increased profitability.
 Objectives and benefits are related but
distinct concepts in maintenance
management.
1.1.2CLASSIFY TYPES OF
MAINTENANCE ORGANIZATIONS.
Maintenance organizations:

• A Maintenance Organization is a group of individuals or entities that are responsible for

maintaining equipment, facilities, or systems.
• Maintenance Organizations can range from small businesses to large multinational corporations
and can be found in a variety of industries such as manufacturing, transportation, and utilities.
• Maintenance Organizations typically include various departments or units, such as maintenance
planning, scheduling, execution, and monitoring.
• The structure of Maintenance Organizations can vary depending on the size and complexity of
the organization, and may include centralized or decentralized models.
• In a centralized model, all maintenance activities are managed by a single department, while in
a decentralized model, maintenance activities are managed by multiple departments or units.
• The type of Maintenance Organization and its structure can have a significant impact on the
efficiency and effectiveness of maintenance activities, as well as overall organizational
performance.
• Examples of Maintenance Organizations include maintenance contractors, in-house
maintenance departments, and third-party maintenance service providers.
In-House Maintenance Organization:

 Employed by large organizations or industries to manage their maintenance

activities in-house.
 The maintenance team may include technicians, engineers, supervisors, and
managers responsible for maintaining the organization's equipment and facilities.
 Example: A large manufacturing company employs a team of technicians, engineers,
and supervisors to maintain its production equipment and facilities.
Contract Maintenance Organization:

 Contracted by an organization to manage its maintenance activities.

 The maintenance team may include technicians, engineers, supervisors, and
managers responsible for maintaining the organization's equipment and facilities.
 The contract may be long-term or short-term, and the scope may vary depending
on the organization's needs.
 Example: An oil refinery contracts a maintenance organization to manage the
maintenance activities of its equipment and facilities.
Outsourced Maintenance Organization:

 Maintenance activities are outsourced to a third-party organization.

 The maintenance team may include technicians, engineers, supervisors, and
managers responsible for maintaining the organization's equipment and facilities.
 The scope of the outsourced maintenance may vary depending on the
organization's needs.
 Example: A hospital outsources its maintenance activities to a third-party
maintenance organization.
Joint Maintenance Organization:

 Joint ownership and management of maintenance activities by two or more

organizations.
 Beneficial in situations where two or more organizations have shared facilities or
equipment that require maintenance.
 Example: Two companies that share a manufacturing facility establish a joint
maintenance organization to manage the maintenance activities of their shared
equipment and facilities.
Centralized Maintenance Organization:

 Centralization of maintenance activities in a single location or department.

 The maintenance team may include technicians, engineers, supervisors, and
managers responsible for maintaining the organization's equipment and facilities.
 Beneficial in situations where there are multiple facilities or equipment that require
maintenance.
 Example: A city government centralizes its maintenance activities for its fleet of
vehicles and equipment in a single department.
Decentralized Maintenance Organization:

 Distribution of maintenance activities across multiple locations or departments.

 The maintenance team may include technicians, engineers, supervisors, and
managers responsible for maintaining the organization's equipment and facilities.
 Beneficial in situations where there are multiple facilities or equipment that require
maintenance.
 Example: A large retail chain distributes its maintenance activities across its multiple
locations, with each location having its own maintenance team.
Hybrid Maintenance Organizations:

 Combines two or more types of maintenance organizations to achieve the desired maintenance
objectives.
 Take advantage of the strengths of different maintenance organization types to achieve their
maintenance objectives more effectively.
 Examples:
 In-house and outsourced maintenance organization: An organization may employ an in-house
maintenance team to manage routine maintenance activities but outsource specialized maintenance
activities to a third-party maintenance organization.
 Joint and centralized maintenance organization: Two or more organizations that share facilities may
establish a centralized maintenance department to manage the maintenance activities of their shared
equipment and facilities.
 Contract and in-house maintenance organization: An organization may employ an in-house
maintenance team to manage routine maintenance activities and contract a maintenance
organization to manage specialized maintenance activities.
 Decentralized and outsourced maintenance organization: An organization may distribute
maintenance activities across multiple locations but outsource the management of those
maintenance activities to a third-party maintenance organization.
1.1.3DIFFERENTIATE TYPES OF
RESPONSIBILITIES/ROLES IN MAINTENANCE
MANAGEMENT ORGANIZATION.
Types of responsibilities/roles:

Maintenance Manager: The maintenance manager is responsible for

planning, organizing, and managing the maintenance activities of an
organization. They oversee the work of maintenance supervisors,
technicians, and engineers, and ensure that maintenance activities are
carried out effectively and efficiently.
Maintenance Supervisor: The maintenance supervisor is responsible for
managing and supervising the work of maintenance technicians and
engineers. They ensure that maintenance activities are carried out
according to the maintenance schedule and quality standards.
Maintenance Technician: The maintenance technician is responsible for
carrying out routine maintenance activities, troubleshooting equipment
problems, and performing repairs as needed. They may also be responsible
for conducting preventive maintenance activities and keeping maintenance
records.
Types of responsibilities/roles:

Maintenance Engineer: The maintenance engineer is responsible for

designing and developing maintenance programs, conducting
equipment analyses, and identifying opportunities for improvement in
the maintenance process. They may also be responsible for developing
maintenance standards and procedures.
Maintenance Planner/Scheduler: The maintenance planner/scheduler
is responsible for developing maintenance schedules and plans,
coordinating maintenance activities with production schedules, and
ensuring that equipment downtime is minimized.
Differentiation of roles:

Maintenance Manager vs. Maintenance Supervisor: The maintenance manager is responsible for
the overall management of maintenance activities and oversees the work of maintenance
supervisors. The maintenance supervisor is responsible for managing and supervising the work
of maintenance technicians and engineers.

Maintenance Technician vs. Maintenance Engineer: The maintenance technician is responsible

for carrying out routine maintenance activities and performing repairs as needed. The
maintenance engineer is responsible for designing and developing maintenance programs and
conducting equipment analyses.

Maintenance Planner/Scheduler vs. Maintenance Manager: The maintenance

planner/scheduler is responsible for developing maintenance schedules and plans and
coordinating maintenance activities with production schedules. The maintenance manager is
responsible for the overall management of maintenance activities.
Real World Examples:

Maintenance Manager: The maintenance manager of a power plant is responsible for managing the
maintenance activities of the plant's equipment, such as turbines and generators.

Maintenance Supervisor: The maintenance supervisor of a manufacturing plant is responsible for

supervising the work of maintenance technicians and engineers who maintain the plant's production
equipment.

Maintenance Technician: A maintenance technician for an airline is responsible for performing routine
maintenance activities on aircraft, such as inspections and repairs.

Maintenance Engineer: A maintenance engineer for a pharmaceutical company is responsible for

developing maintenance programs and procedures for the company's manufacturing equipment.

Maintenance Planner/Scheduler: The maintenance planner/scheduler for a food processing plant is

responsible for developing maintenance schedules and plans for the plant's equipment to minimize
downtime and maximize production efficiency.
MAINTENANCE ORGANIZATION

1.2 CONSTRUCT THE TYPES OF MAINTENANCE COSTS

1.2.1EXPLAIN SOURCES OF
MAINTENANCE COST:
Introduction:

Maintenance cost refers to the cost incurred by an

organization to maintain its assets and equipment in
good working condition. Maintenance cost includes
the cost of labor, materials, and equipment used to
repair, maintain, and replace assets and equipment.
Sources of maintenance cost:

There are several sources of maintenance cost that organizations need to

consider when developing maintenance strategies. These sources include:
 Equipment failure: Equipment failure is one of the main  Spare parts inventory: Organizations need to maintain an
sources of maintenance cost. When equipment fails, inventory of spare parts to carry out maintenance activities.
repairs or replacement must be carried out to bring the The cost of purchasing and storing spare parts is a source of
equipment back to operational condition. maintenance cost.

 Labor costs: The cost of labor to carry out maintenance

 Preventive maintenance: Preventive maintenance activities activities is a source of maintenance cost. This includes the
such as inspections, lubrication, and calibration are cost of in-house maintenance personnel as well as the cost of
carried out to prevent equipment failure. These activities outsourced maintenance services.
also incur maintenance costs.
 Maintenance management software: Maintenance
 Corrective maintenance: Corrective maintenance management software is used to manage maintenance
activities such as repairs and replacements are carried activities and costs. The cost of purchasing and maintaining
out to fix equipment failures. These activities incur this software is a source of maintenance cost.
maintenance costs.

 Predictive maintenance: Predictive maintenance activities

such as vibration analysis and oil analysis are carried out
to predict equipment failures before they occur. These
activities incur maintenance costs.
Real-world examples:

 Equipment failure: An example of equipment failure causing maintenance cost is a broken conveyor belt in a
production line. The cost of replacing the belt and any other damaged equipment will be a maintenance cost.

 Preventive maintenance: An example of preventive maintenance causing maintenance cost is an oil change for a
car. The cost of the oil change and any other preventive maintenance activities will be a maintenance cost.

 Corrective maintenance: An example of corrective maintenance causing maintenance cost is repairing a broken
machine in a factory. The cost of the repairs and any replacement parts will be a maintenance cost.

 Predictive maintenance: An example of predictive maintenance causing maintenance cost is conducting a

vibration analysis on a motor. The cost of the analysis and any subsequent maintenance activities will be a
maintenance cost.

 Spare parts inventory: An example of spare parts inventory causing maintenance cost is purchasing and storing
spare parts for a fleet of trucks. The cost of purchasing and storing the spare parts will be a maintenance cost.

 Labor costs: An example of labor costs causing maintenance cost is hiring an outside contractor to repair a
building's roof. The cost of the contractor's labor will be a maintenance cost.

 Maintenance management software: An example of maintenance management software causing maintenance

cost is purchasing a new software program to manage maintenance activities. The cost of purchasing and
maintaining the software will be a maintenance cost.
1.2.2CLASSIFY TYPES OF
MAINTENANCE COST.
Types of maintenance cost. :

Maintenance cost can be classified into several types based on the

nature of the cost. These types include:
 Direct costs: Direct costs are maintenance costs  Variable costs: Variable costs are maintenance costs
that can be directly attributed to a specific that vary with the level of maintenance activity or the
maintenance activity or asset. These costs include condition of the asset. These costs include labor
labor, materials, and equipment costs. and material costs.

 Indirect costs: Indirect costs are maintenance  Planned costs: Planned costs are maintenance costs
costs that cannot be directly attributed to a that are included in the maintenance budget and are
specific maintenance activity or asset. These planned in advance. These costs include preventive
costs include administrative and overhead costs maintenance, predictive maintenance, and planned
such as salaries of maintenance management corrective maintenance.
staff, utilities, and rent.
 Unplanned costs: Unplanned costs are maintenance
 Fixed costs: Fixed costs are maintenance costs costs that are not included in the maintenance
that do not vary with the level of maintenance budget and occur unexpectedly. These costs include
activity or the condition of the asset. These costs emergency repairs, unscheduled maintenance, and
corrective maintenance due to unexpected failures.
include overhead costs such as rent, insurance,
and taxes.
Real-world examples:

 Direct costs: An example of direct maintenance cost is the cost of replacing a broken pump in a
manufacturing plant. The cost of the replacement pump, labor to install it, and any other materials needed
are direct maintenance costs.

 Indirect costs: An example of indirect maintenance cost is the cost of salaries of maintenance management
staff. This cost cannot be directly attributed to a specific maintenance activity but is necessary for the
overall management of maintenance activities.

 Fixed costs: An example of fixed maintenance cost is the cost of rent for a maintenance facility. This cost
does not vary with the level of maintenance activity or the condition of the assets being maintained.

 Variable costs: An example of variable maintenance cost is the cost of labor to repair a machine. The
amount of labor required to repair the machine will vary depending on the condition of the machine.

 Planned costs: An example of planned maintenance cost is the cost of preventive maintenance for a fleet of
trucks. This cost is planned in advance and includes activities such as oil changes and inspections.

 Unplanned costs: An example of unplanned maintenance cost is the cost of emergency repairs due to a
sudden equipment failure. This cost was not planned for and occurred unexpectedly.
1.2.3DISTINGUISH COST ANALYSIS
METHODS.
Cost Analysis Methods:

Cost analysis is an important aspect of maintenance management that involves identifying,

quantifying, and analyzing the different costs associated with maintenance activities. There are
several cost analysis methods that can be used in maintenance management, including:
 Breakdown analysis: Breakdown analysis involves  Cost-benefit analysis: Cost-benefit analysis
analyzing the costs associated with unplanned involves comparing the costs of maintenance
maintenance activities such as emergency repairs activities with the benefits gained from these
and unscheduled downtime. This analysis helps activities. This analysis helps identify the most
identify the root causes of the breakdown and the cost-effective maintenance strategies based on
associated costs. the expected benefits.

 Reliability analysis: Reliability analysis involves  Value analysis: Value analysis involves identifying
analyzing the costs associated with maintenance and eliminating unnecessary costs associated with
activities aimed at improving the reliability and maintenance activities without compromising
availability of assets. This analysis helps identify quality or performance. This analysis helps
the most cost-effective maintenance strategies. optimize the value of maintenance activities.

 Life cycle cost analysis: Life cycle cost analysis

involves analyzing the costs associated with an
asset over its entire life cycle, including
acquisition, operation, maintenance, and disposal.
This analysis helps identify the most cost-effective
maintenance strategies throughout the life cycle of
the asset.
Real-world examples:

 Breakdown analysis: An example of breakdown analysis is analyzing the costs associated with
emergency repairs due to a sudden equipment failure. This analysis helps identify the root cause of the
failure and the associated costs of the repair.

 Reliability analysis: An example of reliability analysis is analyzing the costs associated with preventive
maintenance activities aimed at improving the reliability and availability of assets. This analysis helps
identify the most cost-effective maintenance strategies.

 Life cycle cost analysis: An example of life cycle cost analysis is analyzing the costs associated with an
asset over its entire life cycle, including acquisition, operation, maintenance, and disposal. This analysis
helps identify the most cost-effective maintenance strategies throughout the life cycle of the asset.

 Cost-benefit analysis: An example of cost-benefit analysis is comparing the costs of preventive

maintenance activities with the benefits gained from these activities. This analysis helps identify the
most cost-effective maintenance strategies based on the expected benefits.

 Value analysis: An example of value analysis is identifying and eliminating unnecessary costs associated
with maintenance activities without compromising quality or performance. This analysis helps optimize
the value of maintenance activities.
1.2.4RELATE COST CONTROL, BUDGET
CONTROL AND FINANCE SYSTEM.
Cost control:

 Cost control is the process of managing and reducing the costs associated with
maintenance activities. This involves identifying the different cost elements and
implementing strategies to reduce these costs while maintaining the required level of
performance and reliability.

 Real-world example:

 An example of cost control is implementing a preventive maintenance program that

helps avoid costly breakdowns and repairs.
Budget control:

 Budget control is the process of managing and controlling the budget for
maintenance activities. This involves setting a budget, monitoring the actual
expenses, and taking corrective actions if necessary to stay within the budget.

 Real-world example:

 An example of budget control is setting a budget for maintenance activities for a

particular year and monitoring the actual expenses to ensure they stay within the
budget. If the actual expenses exceed the budget, corrective actions may need to
be taken to reduce costs.
Finance system:

 A finance system is the set of processes and procedures that a company uses to
manage its financial resources. This includes budgeting, accounting, financial
reporting, and financial analysis.

 Real-world example:

 An example of a finance system is a company's accounting system, which tracks the

expenses associated with maintenance activities and provides financial reports that
help management make informed decisions about budgeting and cost control.
Relation between cost control, budget control, and finance
system:

 Cost control and budget control are closely related because cost control measures
are typically implemented to help stay within the budget. The finance system is also
closely related to cost control and budget control because it provides the financial
information needed to monitor expenses and make informed decisions about cost
control measures and budgeting. Effective cost control and budget control are
essential components of a well-functioning finance system that ensures financial
stability and sustainability.
MAINTENANCE ORGANIZATION

1.3 ORGANIZE TYPES OF MAINTENANCE ORGANIZATION

1.3.1ANALYZE EFFECTIVE AND NON-
EFFECTIVE MAINTENANCE
ORGANIZATION.
Effective maintenance organizations:

 An effective maintenance organization is one that is able to meet its maintenance

goals and objectives while staying within its budget. Some of the characteristics of
effective maintenance organizations include:
 Clearly defined maintenance objectives and strategies.
 Well-trained and competent maintenance personnel.
 Adequate resources, including tools, equipment, and spare parts.
 Effective maintenance planning and scheduling processes.
 Proactive maintenance practices, such as preventive maintenance and condition-based
maintenance.
 Continuous improvement processes to identify and eliminate inefficiencies.

 An example of an effective maintenance organization is an airline maintenance

department that has well-trained mechanics, a comprehensive preventive
maintenance program, and effective processes for managing spare parts inventory.
The department is able to maintain a high level of aircraft availability while staying
within its budget.
Non-effective maintenance organizations:

 A non-effective maintenance organization is one that is unable to meet its

maintenance goals and objectives or is experiencing excessive downtime and repair
costs. Some of the characteristics of non-effective maintenance organizations include:
 Lack of clearly defined maintenance objectives and strategies.
 Inadequate training and competence of maintenance personnel.
 Insufficient resources, including tools, equipment, and spare parts.
 Poor maintenance planning and scheduling processes.
 Reactive maintenance practices, such as corrective maintenance and breakdown maintenance.
 Lack of continuous improvement processes to identify and eliminate inefficiencies.

 An example of a non-effective maintenance organization is a manufacturing plant that

experiences frequent breakdowns and downtime due to a lack of preventive
maintenance and inadequate spare parts inventory. The maintenance department is
often overwhelmed and unable to keep up with the repair demands, leading to
excessive downtime and repair costs.
Effective maintenance organizations vs Non-effective
maintenance organizations:

 Overall, effective maintenance organizations are able to meet their maintenance

goals and objectives while staying within their budget, while non-effective
maintenance organizations struggle to keep up with maintenance demands and
experience excessive downtime and repair costs. By identifying the characteristics
of effective maintenance organizations, non-effective organizations can implement
strategies to improve their maintenance practices and achieve better results.
1.3.2ANALYZE MAINTENANCE
PERFORMANCE OR EVOLUTION.
Maintenance performance analysis:

 Maintenance performance analysis involves measuring and evaluating the effectiveness

and efficiency of maintenance activities. Some of the key metrics used in maintenance
performance analysis include:
1. Mean Time Between Failures (MTBF) – the average time between equipment failures.
2. Mean Time To Repair (MTTR) – the average time required to repair failed equipment.
3. Overall Equipment Effectiveness (OEE) – a measure of the availability, performance, and quality of
equipment.
4. Maintenance Cost as a percentage of Total Production Cost – a measure of the cost of maintenance
relative to the total cost of production.
5. Schedule Compliance – the percentage of scheduled maintenance activities that are completed on time.

 An example of maintenance performance analysis is a mining company that measures

the MTBF and MTTR of its mining equipment. By analyzing these metrics, the company
can identify equipment that is prone to failure and take proactive measures to prevent
downtime. The company can also track its maintenance costs as a percentage of total
production costs to ensure that it is operating efficiently.
Maintenance evolution analysis:

 Maintenance evolution analysis involves evaluating how maintenance practices have

changed over time and identifying areas for improvement. Some of the key areas to
evaluate in maintenance evolution analysis include:
1. Changes in maintenance strategy – such as a shift from reactive to proactive maintenance practices.
2. Changes in maintenance technologies – such as the adoption of new condition monitoring or predictive
maintenance tools.
3. Changes in maintenance organization structure – such as the centralization or decentralization of
maintenance activities.
4. Changes in maintenance performance metrics – such as the addition of new metrics or changes in the
importance placed on certain metrics.

 An example of maintenance evolution analysis is a power plant that has transitioned from
reactive to proactive maintenance practices over time. The plant has implemented a
condition-based maintenance program that uses real-time monitoring data to identify
potential equipment failures before they occur. By analyzing the evolution of its
maintenance practices, the plant can identify areas for further improvement and continue
to optimize its maintenance strategy.
Maintenance performance analysis vs Maintenance evolution
analysis:

 Overall, maintenance performance analysis and maintenance evolution analysis are

important tools for evaluating the effectiveness and efficiency of maintenance
activities. By measuring key metrics and analyzing changes in maintenance
practices over time, organizations can identify areas for improvement and optimize
their maintenance strategy.
1.3.3CLASSIFY MAINTENANCE AUDIT SUCH AS
MAINTENANCE OPERATION AUDIT, MAINTENANCE
PLAN AUDIT AND TECHNICAL AUDIT.
Maintenance Operation Audit:

 Maintenance Operation Audit involves evaluating the performance of maintenance

activities at the operational level. This audit is typically conducted by a maintenance
supervisor or manager and includes an assessment of the following:
 The effectiveness of work order management processes.
 The quality of maintenance work performed.
 The safety of maintenance activities.
 The availability and adequacy of maintenance resources, such as tools, equipment, and spare parts.
 The compliance of maintenance activities with relevant regulations and standards.

 An example of Maintenance Operation Audit is a manufacturing plant that conducts

regular audits of its maintenance operations. The plant evaluates the performance of
its maintenance team by measuring the quality of work performed, the safety of
maintenance activities, and compliance with regulations and standards. By conducting
these audits, the plant can identify areas for improvement and take corrective action
to ensure that maintenance activities are performed efficiently and effectively.
Maintenance Plan Audit:

 Maintenance Plan Audit involves evaluating the maintenance planning and scheduling
processes. This audit is typically conducted by a maintenance planner or scheduling
specialist and includes an assessment of the following:
 The effectiveness of the maintenance planning process, including the accuracy of job plans and the use of
appropriate maintenance procedures.
 The effectiveness of the maintenance scheduling process, including the ability to optimize schedules to
minimize downtime and maximize equipment availability.
 The use of appropriate maintenance tools and systems to support planning and scheduling activities.
 The compliance of maintenance plans and schedules with relevant regulations and standards.

 An example of Maintenance Plan Audit is a transportation company that conducts regular

audits of its maintenance planning and scheduling processes. The company evaluates
the effectiveness of its maintenance planning process by measuring the accuracy of job
plans and the use of appropriate maintenance procedures. The company also evaluates
the effectiveness of its maintenance scheduling process by measuring the ability to
optimize schedules to minimize downtime and maximize equipment availability.
Technical Audit:

 Technical Audit involves evaluating the technical aspects of maintenance activities. This audit
is typically conducted by a maintenance engineer or technical specialist and includes an
assessment of the following:
 The quality of maintenance work performed, including the effectiveness of repairs and the use of appropriate
maintenance procedures.
 The adequacy of equipment design and installation, including the use of appropriate materials and
components.
 The adequacy of maintenance procedures and practices, including the use of appropriate tools and techniques.
 The compliance of maintenance activities with relevant regulations and standards.

 An example of Technical Audit is an oil and gas company that conducts regular audits of its
maintenance activities. The company evaluates the quality of maintenance work performed
by measuring the effectiveness of repairs and the use of appropriate maintenance
procedures. The company also evaluates the adequacy of equipment design and installation
by measuring the use of appropriate materials and components. By conducting these audits,
the company can ensure that its maintenance activities are performed to a high standard and
comply with relevant regulations and standards.
The importance of Maintenance Operation Audit, Maintenance
Plan Audit, and Technical Audit :

 Overall, Maintenance Operation Audit, Maintenance Plan Audit, and Technical Audit
are important tools for evaluating the effectiveness and efficiency of maintenance
activities. By measuring key metrics and analyzing maintenance processes,
organizations can identify areas for improvement and optimize their maintenance
strategy.
1.3.4APPLY KEY PERFORMANCE INDICATORS (KPI)
IN MAINTENANCE REVIEW OR IMPROVEMENT OF
MAINTENANCE SYSTEM AND STRATEGY.
Key Performance Indicators (KPI) in Maintenance:

 KPIs are metrics used to measure the performance and effectiveness of

maintenance management.

 KPIs help to identify areas that require improvement and assist in the decision-
making process.
Types of KPIs in Maintenance:

 Equipment Availability: Measures the percentage of time that equipment is

available for production.

 Equipment Reliability: Measures the number of breakdowns or failures of

equipment in a given period.

 Maintenance Cost: Measures the total cost of maintenance activities in a given

period.

 Maintenance Productivity: Measures the efficiency of maintenance activities,

such as the number of work orders completed per day.

 Mean Time Between Failures (MTBF): Measures the average time between
equipment failures.

 Mean Time to Repair (MTTR): Measures the average time it takes to repair
equipment after a failure.

 OEE (Overall Equipment Effectiveness): Measures the overall efficiency of a

Applying KPIs in Maintenance:

 KPIs can be used to identify areas for improvement in the maintenance

system and strategy.

 For example, if equipment availability is low, KPIs can help to identify the
root cause of the problem and guide improvements in the maintenance
program.

 Regular monitoring of KPIs can help to track progress over time and ensure
that the maintenance system is effective and efficient.
Applying KPIs in Maintenance Review or Improvement of
Maintenance System and Strategy:

1. Define Objectives: Identify the goals and objectives of the maintenance system and strategy. For example,
the objective may be to improve equipment reliability or reduce maintenance costs.

2. Select Relevant KPIs: Select KPIs that are relevant to the objectives of the maintenance system and
strategy. For example, if the objective is to improve equipment reliability, KPIs such as MTBF and MTTR may
be selected.

3. Establish Baselines: Establish baseline values for the selected KPIs. This will help to monitor progress and
identify areas for improvement.

4. Set Targets: Set realistic targets for the KPIs based on the objectives of the maintenance system and
strategy. For example, if the objective is to improve equipment reliability, a target for MTBF may be set.

5. Monitor Performance: Regularly monitor the KPIs to track performance against the established baselines
and targets. This will help to identify areas that require improvement and assist in the decision-making
process.

6. Analyze Data: Analyze the KPI data to identify trends and patterns. This will help to identify the root causes
of problems and guide improvements in the maintenance program.

7. Take Action: Take action to improve the maintenance system and strategy based on the KPI data. For
example, if the MTBF is low, actions such as improving preventive maintenance activities or upgrading
equipment may be taken.

8. Continuously Improve: Continuously review and improve the maintenance system and strategy based on the
KPI data. This will help to ensure that the maintenance program is effective and efficient.