WIXLIB

Phone:Fax:Email:Website: 61 (0) 402 731 563 61 (8) 9457 ability.comSample Maintenance AuditReportNOTES:1.0 This sample maintenance audit report and contents is indicative of the coverage andapproach taken by Lifetime Reliability Solutions Consultants when performing amaintenance audit. Every company is unique and individually analysed and thus eachaudit report is written to reflect the company and the situation we investigate.2.0 This sample document is a construction and is not of a real company. It containsextracts from sections of a range of maintenance audit reports to provide evidence ofour maintenance audit methodology and capability and is otherwise not to be used.Sample Maintenance Audit Report.docxYour Company NamePage 1 of 19

Phone:Fax:Email:Website: 61 (0) 402 731 563 61 (8) 9457 ability.comTable of Contents1.0Introduction . 31.12.0Scope of Work . 3Executive Summary . 42.1Overview of Maintenance Audit Results. 42.2Current Maintenance Capability. 53.0Maintenance Systems Audit Results . 73.1Maintenance Audit Methodology . 73.2Maintenance Audit Objective . 73.3Maintenance Process Capability Performance and Stability . 93.4Prediction of Future Maintenance Performance . 104.0Discussion and Recommendations . 114.1Organisation Culture and Empowerment . 114.2Work Management . 114.3Materials Management . 134.4Key Performance Measurement and Performance Monitoring . 144.5Budgeting & Cost Control . 154.6Information Technology . 165.0Key Improvement Opportunities . 185.1Maintenance Capability . 185.1.1Develop a Maintenance Business Plan (Strategy) . 185.1.1.16.0Reliability Improvement . 18Conclusion . 19Appendix ACompleted Objective Audit Question Set and Audit ResultsAppendix BManagement PowerPoint PresentationAppendix CRecommendations Priority ListAppendix DSample Guidelines for Developing a Maintenance Business PlanAppendix ESample Implementation of Weekly Scheduling ProcedureAppendix FSample Recommended CMMS Fault CodesAppendix GSample Recommended Maintenance KPI GraphsAppendix HSample Major Stoppage (Root Cause Failure Analysis) ProcessAppendix ISample Job Types, Status, Priorities ProcedureAppendix JApplicable Asset Maintenance Management Standards and GuidesSample Maintenance Audit Report.docxYour Company NamePage 2 of 19

Phone:Fax:Email:Website:1.0 61 (0) 402 731 563 61 (8) 9457 ability.comIntroductionThis maintenance audit is a review of the maintenance management processes and practices at Insert Company Name Insert Site Name Operations was prepared by Lifetime ReliabilitySolutions following a request by Insert Name , Maintenance Manager of the operation.1.1 Scope of Work1) Review the current effectiveness of maintenance processes2) Suggest improvements to the content and set up of the computerised maintenancemanagement system (CMMS) at Insert Site ;3) Complete an objective maintenance review, using a spider audit question set; and4) Provide a written report, complete with recommendations for improvement, detailingthe results of the maintenance audit and review.Copies of your maintenance system documents were requestioned and reviewed by the Author tofamiliarise themselves with your operation and to understand the completeness and capability ofyour maintenance processes.A site visit to the Insert Site Processing Plant was undertaken to complete the audit and toreview the general maintenance performance.A PowerPoint presentation was prepared for delivery to the site senior management summarisingthe audit results and key improvement opportunities. (See Appendix B).The comments in this report are based upon reviewing your maintenance processes, doing thesite inspections, the Author‟s previous experience in maintenance, current best practicebenchmarks in asset maintenance management, documentation provided by your personnel anddiscussions with the following personnel. Insert Name -General Manager Insert Name -Operations Manager Insert Name -Maintenance Manager Insert Name -Maintenance Shift Supervisors Insert Name -Maintenance Planner Insert Name -Senior Electrical Supervisor Insert Name -Senior Mechanical Supervisor Insert Name -Maintenance Clerk / CMMS Administrator Insert Name -Stores Superintendent Insert Name -OH&S Advisor Insert Name -Production Manager Insert Name -Production Supervisor Insert Name -Production Shift SupervisorsSample Maintenance Audit Report.docxYour Company NamePage 3 of 19

Phone:Fax:Email:Website:2.0 61 (0) 402 731 563 61 (8) 9457 ability.comExecutive SummaryAt the time of the audit we rate the maintenance performance at the operation as shown on thePlant and equipment Wellness Circle in Figure 1.Failure Prevention, Defect Elimination3T - Target, Tolerance, Test - Precision“I do topqualitywork.”Precision Maintenance, Standards and SpecificationsTotal Quality ManagementReliability Management, Reliability Data Analysis, Shutdown Extension3T Precision ProceduresRisk Management, Equipment Predictive Performance MeasuresTotal Productive Maintenance (TPM), Up-skill Workforce“I want to dotop qualitywork.”Specialist Skills TrainingOccupational Health and Safety, Shutdown ManagementPredictive Maintenance (PdM), Computerised Maintenance Management System (CMMS)ISO 9001 Quality SystemLowMaintenance Management, Operations Management“If it isn’tbrokendon’ttouch it.”Descriptive ProceduresPlanning and Scheduling, Materials ManagementPreventive Maintenance (PM), Historic Performance MeasuresOn-the-job TrainingReactive, Breakdown MaintenanceHigh CostsFinancial AccountingOperating Cost Control“I just dowhat I’mtold.”“”Whatdid itcost?”“WhatJob DescriptionComputerised Maintenance Management System (CMMS)“Whatwentwrong?”Cost Accounting“Wheredid themoneygo?”“Is this the bestway to spendour money?”happened!?”Performance MeasurementEnterprise Resource Planning(ERP)Low“How canwe dobetter withour plant?”“I amexpert inmy job.”Business-Wide IntegratedCollaborative Teams100% Right First TimeAccuracy Controlled EnterpriseScientific Method Process ImprovementProduction Quality“We work together asteams of experts.”Enterprise Asset Management, Quality Management System“Let’sincrease ouruptime.”CultureWorld ClassQuality“Don’t have the problems inthe first place.”“Let’s optimisebusinessperformance.”Enterprise Asset PerformanceOperationalVisionHigh WastageProcessesActivity Based Costing (ABC)Performance MeasurementTeam ManagementSupply Chain ManagementPersonal PerformanceMaximumJourney to Operational Excellence“Let’smanageourselvesbetter.”Team Leadership“How can we makethe most money?”“Let’s find abetter way.”Life Cycle ProfitPersonal Leadership“Let’s know exactlywhat happens in ourbusiness”Capital“Let’s find thebest way.”Profit Contribution MappingFinancialVisionBest PracticePerformancePeopleMaximumLeast CostsDAFT CostingFigure 1 – Progress to Plant and Equipment Wellness2.1 Overview of Maintenance Audit ResultsAn objective maintenance audit was completed by using a targeted questionnaire covering thekey factors for world class maintenance that was developed specifically for the operation (seeAppendix A). The questionnaire allowed us to compare the current effectiveness of maintenanceperformed in the operation with maintenance best practice at other organisations across theworld.The operation‟s total score was 49% out of 100% and individual key area scores were:Sample Maintenance Audit Report.docxYour Company NamePage 4 of 19

Phone:Fax:Email:Website: 61 (0) 402 731 563 61 (8) 9457 ability.comOrganisation Culture and Empowerment44%Performance Measurement41%Work Management64%Asset Management48%Contractor Management38%Budgeting and Cost Control45%Materials Management70%Information Technology43%2.2 Current Maintenance CapabilityMaintenance is being hampered by a lack of maintenance management process knowledgeand/or training in the company‟s Computerised Maintenance Management System (CMMS)which results in not following formalised maintenance processes or procedures.Another useful framework for considering the current status of maintenance in the operation isillustrated by the Maintenance Capability Plot on Table 1. Table 1 provides useful insights onwhere your business has weaknesses and hence the major opportunities available to you for rapidimprovement.Sample Maintenance Audit Report.docxYour Company NamePage 5 of 19

ationStructureHumanResourcesKnowledge nning andSchedulingContractorManagementQuality Systemmanaged AccuracyControlled Enterprisewhere everyone in everydepartment works to 3Terror preventionprocedures; Leanphilosophies improveprocessesBusiness strategy focus;Maximising Life CycleProfit; Defect AndFailure Total (DAFT)Cost database. ProcessStep Contributionmonitoring across allprocessesIntegrated crossfunctional teamsincorporating financial,engineering, operationsand maintenanceEmpowered, flexible,cross-functional teamsof experts working toscientific disciplineContinually learning,pushing-out theboundaries of humanknowledge andunderstanding, SixSigma discipline isnormalPrecision Domain drivesall engineering,installation, operationsand maintenance work;Risk analysis andmanagement normalMaterials problemsdesigned-out, OEMmonitors real-timeinformation on criticalparts‟ condition andcarries necessary sparesMaintenance reducingas continualimprovements extendtime between outages;continually reducingtime to repair with LeanphilosophiesSmall teams of expertsservicing entire localindustry deliveringprecision maintenanceand design-outmaintenance with profitsharingExcellencePersonnel action plans;appraisals are clearlytied to the maintenancestrategyOn-going benchmarkingof metrics andprocesses; Full costdatabaseTotal ProductiveMaintenance whereoperators drivereliability, fault-find andmaintain equipment;root cause failureanalysis by operatorsand maintainersExpert systems used;fully integrated CMMScommon databasePreventive & Predictiveplans continuouslyoptimized; the „right‟maintenance tactic isapplied based onanalysisStores system integratedto CMMS andaccounting system; barcoding or radiofrequency tags of allstores items; Worldclass StoresManagement 90% all maintenance isplanned and 95% firsttime schedulecompliance; rollingschedule fixed for theweek aheadSmall numbers ofcontractors on long termsharing partnershipagreements with highinnovativenessRisk and unplannedfailure reduced to bestin industry by analysisand modellingCompetenceReliability focusedMaintenanceimprovement actionplan is linked to themaintenanceManagement StrategyStatistical processcontrol applied tomaintenance processmeasures; Equipmentspecific maintenancecosts availableEasy access toknowledge basesavailable to allemployees at all timesPreventive & Predictiveplans exist for allmaintainable items;emphasis on PdM. Alltactics understoodSingle source supplierpartnerships establishedand effective; Areastores with visualcontrols; Reliability ofspares maintained;Suppliers providetechnical expertiseLong term assetplanning established;Critical path analysisused for all rebuilds andshutdownsContractors areestablished based onprinciple of „risksharing‟; Contractorsprovide technicalexpertiseEffective Root CauseAnalysis (RCA) appliedto equipment problemsto extend lifeUnderstandingA clear Maintenancevision and strategy isdocumented andcommunicated to allemployeesInput – Output processmeasures reviewed anddisplayed; Downtime bycause; Segregatedmaintenance costsreviewedDecentralized withcentral support; Clearlywritten, mandates/rolesfor each maintenancefunction and groupTrades have problemidentification andsolving; team dynamicsand training skillsDocument controlsystem established;CMMS installed andused to manageknowledge basesPreventive & Predictiveplans exist for keyequipment; Complianceto scheduled plan ismore than 95%Spares classified withseparate strategi

1.0 This sample maintenance audit report and contents is indicative of the coverage and approach taken by Lifetime Reliability Solutions Consultants when performing a maintenance audit. Every company is unique and individually analysed and thus each audit report is written to reflect the company and the situation we investigate.