Auditing your Maintenance Program

#CMMS #Maintenance #EAM #CBM #conditionmonitoring #Reliabilitymanagement #Reliability #Predicitvemaintenance #Preventivemaintenance

Introduction

By following these steps, you can conduct a thorough audit of the maintenance program, identify areas for improvement, and contribute to the overall reliability and efficiency of industrial machines, equipment, assets, and production plants.

Define Audit Objectives

• Clearly outline the objectives of the maintenance program audit, considering factors such as equipment reliability, uptime, cost-effectiveness, and adherence to industry standards.

Review Maintenance Policies and Procedures

• Assess the clarity and accessibility of maintenance policies and procedures.

• Ensure that procedures align with industry best practices, equipment manufacturer recommendations, and safety regulations.

Examine Equipment Criticality Analysis

• Review the criticality analysis of equipment to prioritize maintenance efforts.

• Ensure that high-priority equipment receives appropriate attention and resources.

• Ensure to that the criticality matrix used are easy to use, easy o implement and do not generate complexity to the implementation process

Evaluate Preventive Maintenance (PM) Practices

• Assess the effectiveness of preventive maintenance schedules and tasks. Some tasks may not be needed, some may not exist.

• Review the adherence to PM schedules, and verify that tasks are based on equipment specifications, history and industry standards.

• Integrate automated and triggered PMs where possible, by integrating your CBM data and CBM reporting to your CMMS

Review Predictive Maintenance (PdM) Practices

• Evaluate the implementation of predictive maintenance techniques (vibration analysis, thermography, ultrasound, etc.).

• Verify that PdM technologies are effectively integrated into the maintenance program.

• Verify if the PdM technologies can be integrated to your CMMS

• Ensure to have good, efficient and fully integrated reporting capabilities 

Check Corrective Maintenance Procedures

• Assess the procedures for handling corrective maintenance.

• Ensure to have goo, efficient and integrates solutions for reporting and documentations

• Review response times, resolution efficiency, and documentation practices for corrective maintenance tasks.

Verify Work Order Management

• Evaluate the work order management system for clarity, completeness, and accuracy.

• Confirm that work orders are appropriately prioritized and assigned based on equipment criticality.

Assess Spare Parts Management

• Review the spare parts inventory management system.

• Ensure optimal stock levels, accuracy in inventory records, and efficient procurement processes.

• Ensure proper integrations with your CMMS system and processes.

Evaluate Equipment Downtime Records

• Assess the accuracy and completeness of records related to equipment downtime.

• Identify common causes of downtime and evaluate their impact on production.

• Ensure to have a good root cause analysis process in place

Review Maintenance Budgets

• Evaluate maintenance budgets against actual expenditures.

• Assess the cost-effectiveness of the maintenance program, considering both planned and unplanned expenses.

• Ensure that your inventory are updated according to inventory cost

• Ensure to have good cost tracing towards work orders, asset databank, types of tasks, areas, and other categories to be able to track both labor cost, operational cost, consumables,  lifetime cost, spare-part cost and more. Use historical data to optimize budgets and see which investments that will give good ROI, increased uptime and more. 

Assess Training Programs

• Review training programs for maintenance personnel.

• Ensure that personnel are adequately trained to operate, maintain, and troubleshoot equipment.

Evaluate Safety Procedures

• Assess the effectiveness of safety procedures during maintenance activities.

• Verify that safety protocols are followed and documented consistently.

Check Regulatory Compliance

• Ensure that the maintenance program aligns with relevant safety and environmental regulations.

• Verify that the organization is up-to-date with certifications and compliance requirements.

Assess Equipment Reliability Data

• Review historical data on equipment reliability.

• Identify trends in equipment failures and assess the effectiveness of maintenance strategies in addressing these issues.

Evaluate Contractor Management

• Assess the management of external contractors involved in maintenance activities.

• Confirm that contractors adhere to safety and quality standards.

Review Maintenance KPIs

• Evaluate key performance indicators (KPIs) related to maintenance.

• Assess metrics such as meantime between failures (MTBF), mean time to repair (MTTR), overall equipment effectiveness (OEE), lifespan cost, cost per running hours, consumables, spaceport cost, threat factors and more.

Assess Technology Integration

• If not implemented. Implement a computerized maintenance management systems (CMMS), into the maintenance program.

• Confirm that technology tools are effectively utilized for planning, scheduling, and tracking maintenance activities.

• Ensure to have a good and structures Asset Databank. A easy to access, searchable and fully connected register of all assets and equipment information')

Verify Documentation and Recordkeeping

• Review the documentation of maintenance activities, including work orders, inspection reports, and equipment histories.

• Ensure that records are maintained in an organized and easily accessible manner.

• If your maintenance program still are done with pen and paper. Implement a CMMS system.

Conduct Stakeholder Interviews

• Interview key stakeholders, including maintenance personnel, production operators, and facility managers.

• Gather feedback on the strengths and weaknesses of the maintenance program.

Document the Maintenance Program Audit

• Compile a comprehensive report documenting the findings of the maintenance program audit.

• Include recommendations for improvements and a plan of action for addressing identified issues.

Establish Continuous Improvement Processes

• Implement processes for continuous improvement based on audit findings.

• Encourage regular reviews and updates to the maintenance program to adapt to changing needs and technological advancements.