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Reliability Assessment

Analyzing Maintenance and Reliability Management

"*" indicates required fields

1PART 1 MAINTENANCE ORGANIZATIONS

2PART 2 TRAINING PROGRAMS IN MAINTENANCE

3PART 3 MAINTENANCE WORK ORDERS

4PART 4 MAINTENANCE PLANNING AND SCHEDULING

5PART 5 PREVENTIVE MAINTENANCE

6PART 6 MAINTENANCE INVENTORY AND PURCHASING

7PART 7 MAINTENANCE AUTOMATION

8PART 8 OPERATIONS/FACILITIES INVOLVEMENT

9PART 9 MAINTENANCE REPORTING

10PART 10 PREDICTIVE MAINTENANCE

11PART 11 RELIABILITY ENGINEERING

12PART 12 MAINTENANCE - GENERAL PRACTICES

13PART 13 FINANCIAL OPTIMIZATION

14PART 14 ASSET CARE CONTINUOUS IMPROVEMENT

15PART 15 MAINTENANCE CONTRACTING

16PART 16 DOCUMENT MANAGEMENT

Part 1 Maintenance Organizations

Name*

First Last

Email*

Phone*

Company*

1. The Maintenance Organizational Chart is…*

(Please select one answer that most closely matches your organization)

A. Current and complete

B. Not complete or over 1 year old

C. Not current and not complete

D. None

2. Detailed job descriptions are available for…*

(Please select one answer that most closely matches your organization)

A. All maintenance positions (including supervisors)

B. All maintenance positions (except supervisors)

С. All maintenance supervisors (and no others)

D. Less than 50% of all maintenance positions

E. No job descriptions

3. What is your Maintenance Supervisor to hourly maintenance employee ratio?*

(Please select one answer that most closely matches your organization)

A. 8:1 to 12:1

В. 12:1 to 16:1

C. Less than 8:1

D. More than 16:1

E. No shift maintenance supervisor

4. What is your Maintenance Planner to hourly maintenance employee ratio?*

(Please select one answer that most closely matches your organization)

A. 15:1 to 20:1

B. 10:1 to 15:1

C. 20:1 to 25:1

D. 25:1 to 30:1

E. No planner or anything other than above.

5. How well are your maintenance organization assignments documented?*

(Please select one answer that most closely matches your organization)

A. Responsibilities fully documented

B. Responsibilities clear, good coverage, good dispatching

C. Informal supervision and coordination, some gaps in job coverage

D. Maintenance reports to production/operation

E. Unclear lines of authority, jurisdictional

6. What is the overall attitude and effort of your maintenance organization?*

(Please select one answer that most closely matches your organization)

A. Excellent, pride in workmanship at all levels

B. Steady work rate, professional operation

C. Average work pace, only a few complaints

D. Only occasional good efforts, frequent job delays, many complaints

E. Constant disagreements within maintenance organization and between maintenance and operations/production/facilities

7. How is the organization and cleanliness of shop and maintenance work areas?*

(Please select one answer that most closely matches your organization)

A. Perfect

B. Good (some improvement possible)

C. Fair (major improvement possible)

D. Poor (major improvement required)

E. Unsuitable or nonexistent

8. How efficient or effective are the maintenance and shop work area layout?*

(Please select one answer that most closely matches your organization)

A. Perfect

B. Good (some improvement possible)

C. Fair (major improvement possible)

D. Poor (major improvement required)

E. Unsuitable or nonexistent

9. How are your maintenance tools and equipment quality and quantity?*

(Please select one answer that most closely matches your organization)

A. Perfect

B. Good (some improvement possible)

C. Fair (major improvement possible)

D. Poor (major improvement required)

E. Unsuitable or nonexistent

10. What percent of maintenance personnel are tied to a pay incentive plan based on output?*

(Please select one answer that most closely matches your organization)

A. All

B. Greater than 90%

C. Greater than 75%

D. Greater than 50%

E. Less than 50% or other

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Total of Part 1

Part 2 Training Programs In Maintenance

1. How well are your maintenance supervisors trained?*

(Please select one answer that most closely matches your organization)

A. All are trained when salaried and additional training is mandatory on a scheduled basis

B. All are trained when salaried and additional training is offered on an optional basis

C. The majority are trained when salaried

D. The majority are offered and attend training offered on an infrequent or irregular basis

E. Few are given initial training and little or no additional training is provided

2. How well are you maintenance planner's trained?*

(Please select one answer that most closely matches your organization)

A. All planners/schedulers have been to one or more public seminars providing instruction on maintenance planning and scheduling.

B. All planners/schedulers are provided with a written training program for maintenance planning.

C. All planners/schedulers receive 1 on 1 on the job training for at least 1 month

D. Planner/scheduler training is on the job only

E. There is no planner/scheduler training program

3. How detailed are your planner training subjects?*

(Please select all that apply)

A. Work Order planning and execution

В. Material planning

С. Scheduling practices

D. Project planning

E. None

4. Who is included in your general maintenance and productivity training?*

(Please select one answer that most closely matches your organization)

A. Includes upper management, line supervision, hourly worker, support personnel

B. Includes upper management, line supervision, and hourly workers

C. Includes upper management, and line supervision

D. Is for only upper management

E. No training program

5. Please select the option which most closely aligns with your maintenance craft training.*

(Please select one answer that most closely matches your organization)

A. Training is tied to a pay and progression program

B. Formal job experience is required before employment and on the job training is provided

C. Formal job experience is required before hire

D. Training is provided by on the job experience after hire

E. There are no formal training requirements for hire and no subsequent training is provided

6. Formal maintenance training is provided to all maintenance craft employees at the frequency of…*

(Please select one answer that most closely matches your organization)

A. less than 1 year

B. between 12 to 18 months

C. between 18 to 24 months

D. not to all employees, but to some in any of the above frequencies

E. no training is offered

7. What is the training format for your maintenance training programs?*

(Please select one answer that most closely matches your organization)

A. Training is a mix of classroom and lab exercises

B. Training is all classroom

C. Training is all in lab or workshop environment

D. Training is all on the job

E. No formal craft training program exists

8. Who provides instruction of your training programs?*

(Please select one answer that most closely matches your organization)

A. Training is run by outside contract expert

B. Training is run by staff subject expert

C. Training is run by supervisors

D. Training is run by hourly workers

E. Training program does not exist

9. What is the current quality and skill level of your maintenance workforce?*

(Please select one answer that most closely matches your organization)

A. Perfect

B. Good (some improvement possible)

C. Fair (major improvement possible)

D. Poor (major improvement required)

E. Unsuitable

10. What is the current quality and skill level of your supervisory workforce?*

(Please select one answer that most closely matches your organization)

A. Perfect

B. Good (some improvement possible)

C. Fair (major improvement possible)

D. Poor (major improvement required)

E. Unsuitable

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Total of Part 2

Part 3 Maintenance Work Orders

1. What percent of maintenance man-hours are reported to a work order?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

2. What percent of maintenance materials are charged against a work order number when issued?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

3. What percent of the total jobs performed by maintenance are covered by work orders?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

4. What percent of the work orders processed in the system (either manual or computerized) are tied to an equipment/asset number?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

5. What percent of the work orders are opened under a priority that would be identified as emergency, breakdown, or urgent?*

(Please select one answer that most closely matches your organization)

A. Less than 20%

B. 20 to 29%

C. 30 to 39%

D. Greater than 39%

6. What percent of the work orders are available for historical data analysis?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

7. What percent of the work orders are checked by a qualified individual for work quality and completeness?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

8. What percent of the work orders are closed within 8 weeks from the date requested?*

(Please select one answer that most closely matches your organization)

A. 100%

B. 75%

C. 50%

D. 25%

E. less than 25%

9. What percent of the work orders are generated from preventive maintenance inspections?*

(Please select one answer that most closely matches your organization)

A. 80-100%

В. 60-80%

C. 40-60%

D. 20-40%

E. less than 20%

10. What categories are tracked for maintenance work orders?*

(Select all that apply)

A. Required downtime

B. Required craft hours

C. Required materials

D. Requestor's name

E. None

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Total of Part 3

Part 4 Maintenance Planning and Scheduling

1. What percent of non-emergency work orders are completed within four weeks of the initial request?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 – 90%

C. Between 60 -75%

D. Between 40-75%

E. Less than 40%

2. What considerations are required when planning work?*

(Select all that apply)

A. Craft required

B. Materials required

C. Tools required

D. Specific job instructions or job plan

E. None

3. What percentage of planned work orders experience delays due to poor or incomplete plans?*

(Please select one answer that most closely matches your organization)

A. Less than 10%

B. Between 10- 20%

C. Between 20 - 40%

D. Between 40 - 50%

E. More than 50%

4. Who is responsible for planning the work orders?*

(Please select one answer that most closely matches your organization)

A. A dedicated maintenance planner

B. A maintenance supervisor

C. Each craft technician

D. Anyone else

5. How often are maintenance job schedules issued?*

(Please select one answer that most closely matches your organization)

A. Weekly

B. Bi-weekly

C. Between 3 and 7 days

D. Daily

E. Any other frequency

6. How often is the maintenance and production scheduling meeting held?*

(Please select one answer that most closely matches your organization)

A. Weekly

B. Bi-weekly

C. Between 3 and 7 days

D. Daily

E. Any other frequency

7. The backlog of maintenance work is available and filtered by what categories?*

(Select all that apply)

A. Craft required

В. Department/area requesting

С. Requestor

D. Date needed by

E. None

8. When the job is completed, who is responsible for reporting the actual time, material, downtime, and other information?*

(Please select one answer that most closely matches your organization)

A. The craft technician performing the work

B. The supervisor of the group

C. Anyone else

D. Information is not recorded

9. What percent of the time are the actuals (i.e. time, consumables, etc.) compared to the estimates for monitoring planning effectiveness?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 -75%

D. Between 40 -75%

E. Less than 40%

10. What is the reporting relationship between planners and supervisors?*

(Please select one answer that most closely matches your organization)

A. Both report to the same maintenance manager.

B. The planner reports to the supervisor.

C. The supervisor reports to the planner.

D. The supervisor and planner report to operations/facilities.

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Total of Part 4

Part 5 Preventive Maintenance

1. The preventive maintenance program includes…*

(Select all that apply)

A. Lubrication checklists

B. Detailed inspection checklists

C. Personnel assigned specifically to the PM program

D. Predictive maintenance diagnostics such as vibration analysis, oil sample analysis, infrared heat monitors, etc.

E. None

2. What percent of the pm inspection/task checklists are checked to insure completeness?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

3. What percent of the plant critical equipment is covered by a preventive maintenance program?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

4. What percent of the PM program is checked annually against an equipment item's history to insure good coverage?*

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

5. What percent of the PMs are completed within 1 week of the due date?

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

6. What determines the frequency of a pm inspection or task/service interval?*

(Please select one answer that most closely matches your organization)

A. The program is condition-based.

B. The program is based on a combination of equipment run time and fixed calendar interval.

C. The program is based on equipment run time only.

D. The program is based on calendar intervals.

E. The program is dynamic and is scheduled based on completion date of previous task.

7. What percent of the inspections/tasks include safety information, detailed inspection instructions, material requirements, and labor estimates?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

8. What percent of the corrective action work orders are generated from the PM inspection program?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

9. What percent of the program are PM metrics and results checked annually for time and material estimate accuracy?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 - 75%

D. Between 40 - 75%

E. Less than 40%

10. Who is responsible for performing preventive maintenance tasks?*

(Please select one answer that most closely matches your organization)

A. Dedicated preventive maintenance personnel

B. Specific individuals on each crew

C. Any individual on a crew

D. Entry level craftworkers

E. Operating personnel

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Total of Part 5

Part 6 Maintenance Inventory and Purchasing

1. What percent of the time are materials in stores when required by the maintenance organization?*

(Please select one answer that most closely matches your organization)

A. More than 95%

B. Between 80 - 95%

C. Between 70 - 80%

D. Between 50 – 70%

E. Less than 50%

2. What percent of the items in inventory appear in the maintenance stores catalog?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 - 90%

C. Between 60 -75%

D. Between 40 - 60%

E. Less than 40%

3. Who controls what is stocked as maintenance inventory items?*

(Please select one answer that most closely matches your organization)

A. Maintenance

В. Anyone else

4. How is the maintenance stores catalog, such as part numbers, produced?*

(Please select one answer that most closely matches your organization)

A. Alphabetic and numeric listings

B. Alphabetic only

C. Numeric only

D. Catalog is incomplete or non-existent

5. The aisle/bin location is specified for what percent of the stores’ items?*

(Please select one answer that most closely matches your organization)

A. More than 95%

B. Between 90 - 95%

C. Between 80-90%

D. Between 70-80%

E. Less than 70%

6. What percent of the maintenance items are issued to a work order or account number upon leaving inventory?*

(Please select one answer that most closely matches your organization)

A. More than 95%

B. Between 90 - 95%

C. Between 80-90%

D. Between 70-80%

E. Less than 70%

7. For what percent of the inventory is maximum and minimum levels for the maintenance stores items specified?*

(Please select one answer that most closely matches your organization)

A. More than 95%

B. Between 90 - 95%

C. Between 80-90%

D. Between 70-80%

E. Less than 70%

8. What percent of the critical maintenance material is stocked in the warehouse or in a location readily accessible when the material is required?*

(Please select one answer that most closely matches your organization)

A. More than 95%

B. Between 90 - 95%

C. Between 80-90%

D. Between 70-80%

E. Less than 70%

9. What percent of the time are maintenance inventory levels updated daily upon receipt of materials?*

(Please select one answer that most closely matches your organization)

A. More than 95%

B. Between 90 - 95%

C. Between 80-90%

D. Between 70-80%

E. Less than 70%

10. What percent of the items are checked for at least one issue every six months?*

(Please select one answer that most closely matches your organization)

A. More than 90%

В. Between 80 - 90%

C. Between 70 - 80%

D. Between 50 - 70%

E. Less than 50%

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Total of Part 6

Part 7 Maintenance Automation

1. What percentage of all maintenance operations utilize a CMMS?*

(Please select one answer that most closely matches your organization)

A. More than 90%

В. Between 75 -90%

С. Between 60 -75%

D. Between 40-75%

E. Less than 40%

2. What percentage of maintenance activities are planned and scheduled through the CMMS?*

(Please select one answer that most closely matches your organization)

A. More than 90%

В. Between 75 -90%

С. Between 60 -75%

D. Between 40-75%

E. Less than 40%

3. What percentage of the maintenance inventory and purchasing functions are performed in the system?*

(Please select one answer that most closely matches your organization)

A. More than 90%

В. Between 75 -90%

С. Between 60 -75%

D. Between 40-75%

E. Less than 40%

4. How is the CMMS and production scheduling systems connected?*

(Please select one answer that most closely matches your organization)

A. Integrated

В. Interfaced

С. There is no connection.

5. How are the CMMS and the payroll/ timekeeping system connected?*

(Please select one answer that most closely matches your organization)

A. Integrated

В. Interfaced

С. There is no connection.

6. How are the CMMS and the financial/accounting system connected?*

(Please select one answer that most closely matches your organization)

A. Integrated

В. Interfaced

С. There is no connection.

7. What percent of the maintenance personnel are using the system for their job functions with a high level of proficiency?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 -90%

C. Between 60 - 75%

D. Between 40- 59%

E. Less than 40%

8. How much CMMS data is structured and maintained to facilitate reporting?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 -90%

C. Between 60 - 75%

D. Between 40- 59%

E. Less than 40%

9. Is CMMS data utilized on a regular basis to make cost-effective management decisions?*

(Please select one answer that most closely matches your organization)

A. Yes

В. Sometimes

C. No

10. Is CMMS data used to verify progressive ROI?*

(Please select one answer that most closely matches your organization)

A. Yes

C. No

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Total of Part 7

Part 8 Operations/Facilities Involvement

1. What percent of operations personnel generate work order requests?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 -90%

C. Between 60-75%

D. Between 40 - 60%

E. Less than 40%

2. What percent of facilities personnel generate work order requests?*

(Please select one answer that most closely matches your organization)

A. More than 90%

B. Between 75 -90%

C. Between 60-75%

D. Between 40 - 60%

E. Less than 40%

3. How are the operations work order priority set for maintenance?*

(Please select one answer that most closely matches your organization)

A. Weekly in a joint Operations / Maintenance meeting

B. Daily in a joint Operations / Maintenance meeting

C. It is set by Maintenance with minimal Operations input

D. It is random and based on emergency needs

4. How is facility work order priority is set for maintenance?*

(Please select one answer that most closely matches your organization)

A. Weekly in a joint Facility/Maintenance meeting

В. Daily in a joint Facility/Maintenance meeting

C. It is set by Maintenance with minimal Facilities input.

D. It is random and based on emergency needs.

5. Are operations/operators responsible and involved in the upkeep and performance of assets?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

6. What tasks are the operators trained and certified to perform?*

(Select all that apply)

A. Inspections

B. Lubrication

C. Minor maintenance task

D. Assist in maintenance repair work

E. None

7. How often do operators follow-up and have a sign-off on completed work orders?*

(Please select one answer that most closely matches your organization)

A. 90% of the time

В. 75 - 90% of the time

C. 60 - 75% of the time

D. 40 - 60% of the time

E. Less than 40% of the time

8. Facilities personnel follow-up and have a sign-off on completed work orders?*

(Please select one answer that most closely matches your organization)

A. 90% of the time

В. 75 - 90% of the time

C. 60 - 75% of the time

D. 40 - 60% of the time

E. Less than 40% of the time

9. How often is Maintenance included in production/process scheduling meetings?*

(Please select one answer that most closely matches your organization)

A. All of the time

B. Most of the time

C. Occasionally

D. Seldom

E. Never

10. Does asset-focused communication exists among maintenance, operations, engineering, and facilities personnel?*

(Please select one answer that most closely matches your organization)

A. All of the time

B. Most of the time

C. Occasionally

D. Seldom

E. Never

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Total of Part 8

Part 9 Maintenance Reporting

1. What percent of the time are the maintenance reports distributed or available on a timely basis to the appropriate personnel?*

(Please select one answer that most closely matches your organization)

A. More than 90%

В. Between 75 -90%

C. Between 60-75%

D. Between 40-60%

E. Less than 40%

2. What percent of the time are the reports distributed or available within 1 day of the end of the time period specified in the report?*

(Please select one answer that most closely matches your organization)

A. More than 90%

В. Between 75 -90%

C. Between 60-75%

D. Between 40-60%

E. Less than 40%

3. Which of the following equipment reports do you produce?*

(Select all that apply)

A. Equipment downtime in order of highest to lowest total hours (weekly or monthly)

B. Equipment downtime in order of highest to lowest in total lost production dollars (weekly or monthly)

C. Maintenance cost for equipment in order of highest to lowest (weekly or monthly)

D. MTTR and MTBF for equipment

E. None

4. Which of the following preventive maintenance reports do you produce?*

(Select all that apply)

А. PM overdue in order of oldest to most recent

B. PM cost per equipment item in descending order

C. PM hours versus total maintenance hours per item, expressed as a percentage

D. PM costs versus total maintenance costs per equipment item, expressed as a percentage

E. None

5. Which of the following personnel reports do you produce?*

(Select all that apply)

A. Time report showing hours worked by employee divided by work order

B. Time report showing hours worked by craft in each department/area

C. Time report showing total hours spent by craft on emergency/preventive normal work

D. Time report showing total overtime hours compared to regular hours

E. None

6. Which of the following planning reports do you produce?*

(Select all that apply)

A. Total work order costs estimated versus total work order actual costs by individual work order, or by craft

B. A backlog report showing the total hours ready to schedule versus the craft capacity per week

C. A planning efficiency report showing the hours and materials planned versus the actual hours and materials used per work order

D. A planning effectiveness report showing the number of jobs closed out that were 20% over or under the labor or material estimates by planner and supervisor

E. None

7. Which of the following scheduling reports do you produce?*

(Select all that apply)

A. Hours worked as scheduled compared to actual hours worked

В. Weekly crew or craft capacity averaged for the last 20 weeks

C. Total number of maintenance work orders scheduled compared to the actual number of work orders completed

D. Number of work orders spent on preventive maintenance compared to emergency maintenance and normal maintenance

E. None

8. Which of the following inventory reports do you produce?*

(Select all that apply)

A. Stock catalog by alphabetical and numerical listing

B. Inventory valuation report

C. Inventory performance report showing stock outs, level of service, turnover rate, etc.

D. Inventory where used report

E. None

9. Which of the following purchasing reports do you produce?*

(Select all that apply)

A. Vendor performance showing promised and actual delivery dates

B. Price performance, showing the quoted and actual prices

C. Buyer or purchasing agent performance report

D. Non-stock report showing all direct buys for items not carried in stock for a specified period

E. None

10. Which of the following administrative reports do you produce?*

(Select all that apply)

A. Monthly maintenance costs versus monthly maintenance budget with a year to date total

B. Comparison of labor and material costs as a percentage of total maintenance costs

C. Total costs of outside contractor usage broken down by contractor / project

D. Maintenance cost per unit of production (or by square foot for facilities)

E. None

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Total of Part 9

Part 10 Predictive Maintenance

1. The predictive maintenance program includes vibration analysis for which of the following?*

(Please select one answer that most closely matches your organization)

A. Critical/Non-critical assets

B. Critical only

C. None

2. The predictive maintenance program includes thermography for which of the following?*

(Please select one answer that most closely matches your organization)

A. Critical/Non-critical assets

B. Critical only

C. None

3. The predictive maintenance program includes oil analysis for which of the following?*

(Please select one answer that most closely matches your organization)

A. Critical/Non-critical assets

B. Critical only

C. None

4. The predictive maintenance program utilizes ultrasonic or ultrasound techniques for which of the following?*

(Please select one answer that most closely matches your organization)

A. Critical/Non-critical assets

B. Critical only

C. None

5. Is condition-based monitoring included in the predictive maintenance program?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

6. What is the relationship between the predictive maintenance system and the CMMS?*

(Please select one answer that most closely matches your organization)

A. Integrated

B. Interfaced

C. Not electronically connected

7. Is the predictive maintenance data used to generate preventive or corrective maintenance work orders?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

8. Is specific personnel exclusively assigned to the predictive maintenance program?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

9. Is predictive work included as part of the weekly work schedule?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

10. Is predictive maintenance data used to improve asset performance and life expectancy?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

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Total of Part 10

Part 11 Reliability Engineering

1. Does the organization have a reliability engineering attitude or mentality?*

(Please select one answer that most closely matches your organization)

A. Yes, it exists as part of the work culture

B. Yes, it exists and is being developed as part of the work culture

C. No

2. What percentage of assets have complete and accurate asset data available for reliability-centered maintenance analysis?*

(Please select one answer that most closely matches your organization)

A. 90% of the assets

В. 75-90% of the assets

C. 60 - 75% of the assets

D. 40-60% of the assets

E. Less than 40% of the assets

3. Is the reliability-centered maintenance (RCM) methodology used to adjust or refine the PM and PDM program?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

4. How often is reliability-centered maintenance analysis conducted on all assets?*

(Please select one answer that most closely matches your organization)

A. Annually

B. Every 6 months

C. Every 2 years

D. Every 3 years

E. Any longer

5. What percentage of the assets is the work order history is accurate in tracking the causes of failures?*

(Please select one answer that most closely matches your organization)

A. 90% of the asset's history

B. 75-90% of the asset's history

C. 60-75% of the asset's history

D. 40-60% of the asset's history

E. Less than 40% of the asset's history

6. What percentage of asset history are failures clearly identified?*

(Please select one answer that most closely matches your organization)

A. 90% of the asset's history

B. 75-90% of the asset's history

C. 60-75% of the asset's history

D. 40-60% of the asset's history

E. Less than 40% of the asset's history

7. Are failure analyses being conducted using analysis tools such as "5 whys," fishbone, pareto, etc., to assure the accuracy and consistency of the effort?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

8. Are dedicated personnel permanently assigned to maintain the reliability-centered maintenance program?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

9. Does management view reliability-centered maintenance as a value-added activity?*

A. Yes

B. No

10. Are there methods in place for measuring the effectiveness of the reliability engineering effort?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

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Total of Part 11

Part 12 Maintenance - General Practices

1. Is the entirety of the organization focused on asset management, utilization, and optimization?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

2. The maintaining function is perceived as value added by:*

(Select all that apply)

A. Management

B. Operations

C. Maintenance

D. Stores and Purchasing

E. None

3. The maintenance data collection system (CMMS/EAM) is utilized by:*

(Select all that apply)

A. Management

B. Operations

C. Maintenance

D. Stores and Purchasing

E. None

4. Are the operators used for first-line maintenance functions?*

(Please select one answer that most closely matches your organization)

A. Yes, in all areas

B. Yes, in some areas

C. Yes, in a few areas

D. No, operators are not used at all

5. What percentage of the time is the overall equipment effectiveness (OEE) calculated on key assets, processes, and facilities?*

(Please select one answer that most closely matches your organization)

A. >90%

B. > 60%

C. > 30%

D. < 30%

6. What percentage of the time are operational decisions made considering equipment reliability and availability?*

(Please select one answer that most closely matches your organization)

A. > 90% of the time

B. > 60% of the time

C. > 30% of the time

D.< 30% of the time

7. On what percentage of personnel have the right "soft skills" training classes been conducted?*

(Examples of soft skills are communications, leadership, etc.)

A. > 90% of the personnel

B. > 60% of the personnel

C. > 30% of the personnel

D. < 30% of the personnel

8. On what percentage have the right "technical" training classes been conducted for appropriate personnel (e.g., maintenance and operations)?*

(Please select one answer that most closely matches your organization)

A. > 90% of the personnel

B. > 60% of the personnel

C. > 30% of the personnel

D. < 30% of the personnel

9. Does the maintenance program comply with regulatory requirements and programs?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

10. Are the financial effects of equipment availability and reliability understood and communicated to everyone?*

(Please select one answer that most closely matches your organization)

A. Yes

B. No

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Total of Part 12

Part 13 Financial Optimization

1. Is downtime duration consistently tracked?*

(Please select one answer that most closely matches your organization)

A. Yes, for all assets

B. Yes, but for key assets only

C. No, not tracked at all

2. Is downtime cost clearly identified for key assets, processes, and facilities?*

(Please select one answer that most closely matches your organization)

A. Yes, for all areas

В. Yes, but for key areas only

C. No, not tracked at all

3. Are root causes of downtime accurately and consistently tracked?*

(Please select one answer that most closely matches your organization)

A. Yes, for all assets

B. Yes, but for key assets only

C. No, not tracked at all

4. Are maintenance costs clearly and accurately tracked?*

(Please select one answer that most closely matches your organization)

A. Yes, for all assets

B. Yes, for key assets only

C. No, not tracked at all

5. What portion of other contributing costs (energy, quality, contractors) are available for analysis?*

(Please select one answer that most closely matches your organization)

A. All the costs

В. Some of the costs

C. None of the costs

6. Are total life cycle costs compared when making decisions?*

(Please select one answer that most closely matches your organization)

A. All cost factors

B. Some cost factors

C. No cost factors

7. Efficiency loss costs are available and accurate for what percentage of the assets?*

(Please select one answer that most closely matches your organization)

A. 90% of the assets

B. 60 -90% of the assets

С. 40 - 60% of the assets

D. 30 - 39% of the assets

E. Less than 30% of the assets

8. Is a dedicated individual or team assigned to analyze financial costs?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

9. Are stores and purchasing costs accurately tracked*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

10. How available is financial information?*

(Please select one answer that most closely matches your organization)

A. Available on demand

B. Available daily

C. Available weekly

D. Available monthly

E. Not available

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Total of Part 13

Part 14 Asset Care Continuous Improvement

1. Is there visible management support for continuous improvement efforts?*

(Please select one answer that most closely matches your organization)

A. Strong support

B. Moderate support

C. Weak support

D. None

2. Does the organization support continuous improvement efforts?*

(Please select one answer that most closely matches your organization)

A. Strong support

B. Moderate support

C. Weak support

D.None

3. If the company has recently downsized, has it affected the organization?*

(Please select one answer that most closely matches your organization)

A. Positive effect

B. No effect

С. Adverse effect

4. What is the observed level of organizational support for continuous improvement?*

(Please select one answer that most closely matches your organization)

A. Excellent

B. Good

C. Poor

5. What is the observed level of cooperation between plant management and labor?*

(Please select one answer that most closely matches your organization)

A. Excellent

B. Good

C. Poor

6. The following personnel are focused on continuous improvement:*

(Select all that apply)

A. Management

B. Maintenance

C. Stores/Purchasing

D. All other personnel

E. No one

7. Does management support on-going training designed to enhance employee skills?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

8. Do continuous improvement efforts focus on ROI?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

9. Are continuous improvement efforts tied to reliability engineering?*

(Please select one answer that most closely matches your organization)

A. Yes

В. No

10. How often do competitive forces influence continuous improvement efforts?*

(Please select one answer that most closely matches your organization)

A. 90% of the time

B. 60-90% of the time

C. 40 - 60% of the time

D. 30-40% of the time

E. Less than 30% of the time

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Total of Part 14

Part 15 Maintenance Contracting

1. The contract request process includes:*

(Select all that apply)

A. A formal process for requesting contract work

B. An established approval process based on dollar value

C. A mechanism to control what is and is not contracted

D. The request process is automated

E. No one

2. Who is responsible for the contracting of work?*

(Please select one answer that most closely matches your organization)

A. Is handled by a contract specialist function solely focused on contracts

B. Is handled by a contract function but not solely focused on contracting

C. Is handled by various job functions who have contracting responsibility

D. Contracting is handled by whoever needs contract work

3. The approved contractors list includes:*

(Select all that apply)

A. A primary contractor for all required services

B. An alternate in the event the primary is unavailable

C. Validated requirements such as insurance, crafts rates, etc.

D. Phone numbers for all contacts

E. None of these

4. What level of supervision does the contractor provide for contracted field execution?*

(Please select one answer that most closely matches your organization)

A. Dedicated company personnel to administer the contract in the field

B. Company personnel to administer the contracts, but it is not their primary function

C. There is no organizational structure to administer field execution

5. What level of responsibility is provided for contractor safety?*

(Please select one answer that most closely matches your organization)

A. A joint effort (joint accountability) between the site and the contractors

B. Highly important and the contractors are held accountable

C. Equally important with the execution of the work

D. Not as important as work execution

6. The computer systems exist with the following contracting functionality on the front end of the process:*

(Select all that apply)

A. Contract requisition

B. Contract administration

C. Contract approval processing

D. Administration of contracts in the field, releasing of work

E. If there is no electronic contract system

7. The computer systems exist with the following contracting functionality on the back end of the process:*

(Select all that apply)

A. Contract employees linked to contract (rates, skills, certifications, etc.)

B. Electronic timesheets, paperless system

C. Gate security electronically linked

D. Invoice payment processes

E. If there is no electronic contract system

8. What is the relationship between the contracting system and the CMMS?*

(Please select one answer that most closely matches your organization)

A. Integrated with the site's CMMS

B. A fully functional system with interfaces to the site CMMS

C. A stand-alone system

D. There is no system

9. What is the relationship between the site personnel and the site contractors?*

(Please select one answer that most closely matches your organization)

A. A partnership focused on efficient and effective work execution

В. A supportive-superior / subordinate relationship

C. Contractors are accepted but not part of the team effort

D. Adversarial; they are a necessary evil

10. How developed is the invoicing and cost-tracking process for contractors?*

(Please select one answer that most closely matches your organization)

A. Highly developed so that those responsible know the costs daily

B. Moderately developed; costs are available weekly

C. The costs are only known when invoices are processed (long lead time)

D. Costs are not readily available to those controlling the work

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Total of Part 15

Part 16 Document Management

1. What is the relationship between the site's document management system and the CMMS/EAM?*

(Please select one answer that most closely matches your organization)

A. Electronic and fully integrated with other systems

B. Electronic and interfaced with other systems

C. Electronic but stand-alone

D. Paper – non electronic

2. What is the percentage of drawings available in the document management system?*

(Please select one answer that most closely matches your organization)

A. 80% to 100%

В. 50% to 80%

C. 30% to 50%

D. less than 30%

3. What is the site's timing for migration to a fully functional and utilized document management system?*

(Please select one answer that most closely matches your organization)

A. 1 to 3 years

B. 3 to 5 years

C. 5 or more years

D. No plan

4. Do document control procedures and associated work processes exist?*

(Please select one answer that most closely matches your organization)

A. Exist for the system

B. Are under development

C. Do not exist

5. What is the level of progress of training on the document system for the personnel?*

(Please select one answer that most closely matches your organization)

A. All have received training; fully understand and use the document management procedures

B. Are in the process of being trained to use the procedures

C. Do not follow the procedures or they do not exist

6. The system has detailed indexing and search capabilities that…*

(Please select one answer that most closely matches your organization)

A. Make documents simple and easy to find

B. Make documents difficult to find

C. Indexing and search capability does not exist

7. What is the level of accessibility for users of the document management system?*

(Please select one answer that most closely matches your organization)

A. Users have access and it is easy to obtain information

B. Users have access, but it is hard to find information

C. Users must go to a separate group who provides the information

D. Information is not accessible for most users

8. What is the quality level of document version control?*

(Please select one answer that most closely matches your organization)

A. Excellent

B. Good

C. Average

D. Poor

E. Very Poor

9. What is the percentage of documents included in the system?*

(Please select one answer that most closely matches your organization)

A. 80% to 100%

В. 50% to 80%

C. 30% to 50%

D. less than 30%

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Total of Part 16

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Total

5637566941

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