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An Educational Reliability & Maintenance Audit and Benchmarking Tool


	Products - What we do
	Current Best Practices Assessment and Educational Exercise
	Planning and Scheduling Consulting Training
	Preventive Maintenance Essential Care and Condition Monitoring Training Definitions PM Software
	Spare Parts Management Consulting Training
	Root Cause Problem Elimination Training Facilitator
	Results Oriented Maintenance Seminars
	Maintenance Productivity Simulation

IDCON has developed a reliability and maintenance audit and benchmarking process based on best practices in industry. The best practices have been defined over the years as we have worked with over 300 organizations all over the world. We have decided to call our reliability and maintenance audit process “Current Best Practices” (CBP) since best practices may change over time. The statements we call CBP has been used by many companies, but they have also been verified and scrutinized by many different types of corporations such as Mining (Arch Coal), Primary Metals (Swedish Steel SSAB, Kaiser Aluminum), Food (Fonterra), Pulp & Paper (UPM Kymmene, Smurfit Stone, Tembec), Wood (Norbord), Chemical (ICL Performance). These companies use the CBP for their reliability vision.

About the CBP Documentation
The current best practice reliability and maintenance audit documentation is built by around 300 statement(s) that focus on WHAT are the right things to do in order to improve reliability and drive down costs. The 300 elements are divided into the following categories:

Leadership and organization
Preventive Maintenance/ essential care and condition monitoring
Planning and scheduling
Root cause problem elimination
Materials management
Facilities, Tools, and Workshops
Engineering’s interface with Maintenance
Technical Database
Skills Development

When we perform a reliability and maintenance benchmarking audit, we compare current practices with our CBP. The gap is identified and scored. Example from Sub-Process Leadership & Organization:

CBP

Element CBP

Score

(scale 1-100)

Element Actual (from an anonymous plant)

Operations and Maintenance work in a partnership.

Maintenance is viewed as a service organization. Priorities for maintenance work are set by operations. Maintenance will occasionally have input on priorities.

Figure: Example of how 1 element of 300 in our CBP documentation could be assessed.

Each CBP is scored and commented on in order to document the gap. Each category is scored and the score can be compared to other companies in order to benchmark the reliability and maintenance performance of your organization. However, the gap is primarily used for two things:

Educate the organization of what the gap is (how good you are compared how could you could be)
Use the gap to agree on an implementation plan for improvement.

Articles we have written on the subject of assessments and benchmarking:

Also, read our Results Oriented Reliability and Maintenance book.