132 Appendix I

Appendix I
The Maintenance Excellence Arch
The Road to Reliability

PD

SA

FE

ISO
QA

TY

(17)
B

(11)

T
JI

(8)

EQ

TRAININ
G

(7) ORGANIZATION
MANAGEMENT
REPORTING
AND CONTROL

WORK/J OB
PLANNING

(18)

(14)

MASTER
PLAN

COST
DI STRIBUTION

(13)

OBJECTIVES
GOALS
AND TARGETS

WORK ORDER
SYSTEM

(12)

STATUS
ASSESSMENT

GOVERNING
PRI NCIPLES
AND CONCEPTS

(1)

BUDGETARY
CONTROL

(4)

COOPERATIVE MAINTENANCE / OPERATIONS PARTNERSHIP

MANAGEMENT COMMITMENT

PROGRAM FOUNDATION

(2)

(19)

COMPUTER
SUPPORT

(5)

(3)

INTEGRATED
PROACTIVE
PARTICIPATIVE

WORK
MEASUREMENT

INFORMATIONAL
SOURCES

SCORE KEEPING

(6)

WORLD
CLASS
OPERATION

Y
OR
G (21)
ST
IN
HI
UL
D
N
HE ND
SC A INATIO
D
OR
L
CO ATERIA
(20)
M
RT
SUPPO
AND CONTROL

R V SH
IP
A IS
PRA ND ION
CTIC
ES

IC

M
(9) SUPE AN

(15)

RV

RK

(16)

SE

D
AN
IES NT
ILIT
Y
E
IT
FAC
PM
AL
UI
QU D
E
ID AN
PR

EQ

(10)

PREVENTIVE
PREDICTIVE
MAINTENANCE

MA
EN INTE
N
GI
NE ANCE
ER
UI
IN
PM
G
EN
T

Appendix I 133
Explanation of the Maintenance Arch
The arch reflects integration of twenty-one building blocks essential to achievement of reliability excellence. It is built upon bedrock of sustained management
commitment, support, involvement, and funding. Upon
the bedrock is formed a footer reflecting the essential
Operations/Maintenance Partnership. Neither function
can achieve reliability without support from each other as
well as from the entire organization.
The banners flying from the Arch reflect the many
management initiatives that are maintenance dependent
(Just-in-Time, Loss Prevention, Employee Safety,
Avoidance of Property Damage, Certification, Quality
Assurance, Avoidance of Business Interruption, and
Customer Service).
The building blocks are interdependent. It is of little sustainable benefit to undertake improvement of one
without addressing needs of the others:
Successful endeavors begin with shared beliefs
(Governing Principles). Status Assessment establishes the current state relative to beliefs. The Master Plan
sets forth actions, resources, responsibilities, and time
lines required to close the gap between current state
and established Objectives, Goals, and Targets. Budget
refinement is required to support the Master Plan.

134 Appendix I
Preventive/Predictive Maintenance is the keystone of
the Arch and is the vehicle by which reliability is
assured. It requires a strong Maintenance/Reliability
Engineering function using Equipment History and
deploying Root Cause Failure Analysis to optimize
PM/PdM routines.
Organization must support proactive reliability not
simply reactive response. Skills Training and
Facilities, Tools and Equipment in which technicians
can take Pride are essential if Supervision is to achieve
functional Quality Assurance and adherence to established policies and procedures.
Planning and Materials Support are essential for
Maintenance is to properly perform the right work in
the first instance. Work Measurement, Coordination,
and Scheduling establish the expectations for each
week.
The Computerized Work Order System with reliable
Cost Distribution feed into Management Reporting,
thereby providing the feedback by which sustained
commitment is earned.
Reliability requires total commitment, partnership,
integration, and pro-activity resulting in cultural change.
Independent changes do not lead to reformation of the
business entity. It is not just the independent building
blocks, but also the manner in which they are erected. A
number of integrated and harmonious changes are
required to achieve a quantum leap forward.