Benchmarking Best Practices for Maintenance, Reliability and Asset Management, Third Edition

However, that calculation leaves out the cost of lost production. The range for this cost may be from two to fifteen times the cost of the maintenance repair as illustrated in Figure F-14. The average ratio is usually 4:1.

While most will agree that maintenance costs are high, they don’t know how high they are for their own site

. Many companies try to remedy maintenance materials problems by overstocking the storeroom

Depending on the type of operation/facility maintenance materials can range between 40–60% of the maintenance budget (see averages in Figure F-13). To successfully manage maintenance, materials must be given close scrutiny.

The lack of the technician’s skills and training leads to substandard performance of the lubrication program. This results in excessive breakdowns, even though a company has a lubrication program. To be successful, maintenance organizations must go beyond the preliminaries and fully develop preventive maintenance programs

Related to preventive maintenance, almost three-fourths of the organizations have some form of lube routes and procedures (see Figure F-11

Preventive maintenance, another major part of any successful maintenance program is presently satisfying the needs of about 22% of the company’s surveyed (see Figure F-10).

. For an operation to be cost effective, good practice in failure analysis (commonly called Root Cause Analysis or RCA) must be followed. We will discuss this topic in Chapter 9

actually 10% of total organizations (see Figure F-5 and F-6). The craft backlog allows managers to make logical staffing decisions based on how much work is projected for each craft

The majority of all maintenance organizations either are dissatisfied with or do not have work order systems (see Figure F-4). T