Step 1 from 10 10% What goals are you pursuing in your maintenance organisation? Ensuring compliance with the legal requirements relating to occupational safety and environmental protection Sustainability goals (energy consumption, circular economy) Budget and cost control Performance and availability targets Optimisation of the maintenance organisation Improving documentation How are the goals of maintenance currently mapped in your company? The maintenance division has its own targets; there is only an indirect link to higher-level corporate goals. The maintenance targets are part of a company-wide target system that also maps the interaction with other areas There are no explicit targets for maintenance. Which maintenance objects are significantly looked after? Machinery and equipment Process and process technology Real estate and properties Safety devices Infrastructure objects How would you currently assess the average availability of machinery, equipment and operating resources in your company?An assessment is not possible for me due to insufficient dataUnder 80Between 80 - 90Over 90 What criteria play a role in determining the maintenance strategy? Experience of the employees Cost comparison of different maintenance strategies Risk assessment (default costs x probability of occurrence) Existing resources and competences Other (please specify) Other criteria Add RemoveWhich maintenance strategies dominate everyday operations? Failure-dependent repair Scheduled maintenance Performance-based maintenance Condition monitoring Prediction-based and predictive maintenance Which standardised management systems are implemented in your company? Quality management (e.g. ISO 9001) Environmental management (e.g. ISO 14001) Safety management (e.g. OHSAS 18001) Energy management (e.g. EN 16001) Risk management (e.g. ONR 49000) None Which tools and methods are used in maintenance management? Process analysis Regular, standardised audits FMEA analysis ABC analysis and other frequency distributions Cause-effect diagrams Scorecards Value stream analysis Condition monitoring Poka Yoke Other (please specify) Other methods Add RemoveAre structured management methods applied? Lean management TPM (Total Productive Maintenance) TQM (Total Quality Management Six Sigma RCM (Reliability Centered Maintenance) RBM (Risk Based Maintenance) MbO (Management by Objectives) Other (please specify) Other management methods Add RemoveWhich technical procedures for condition monitoring are currently used or planned? Vibration diagnosis Current consumption and power monitoring Monitoring of process parameters Thermography Evaluation of existing sensors Other (please specify) Further methods for condition monitoring Add RemoveAre technical resources (special tools, measuring equipment, analysis technologies) used as part of the inspection? Various technical aids are used to record the evaluation of machine conditions Test and measuring equipment is used for which test equipment management is required Capacity planning is required to ensure that tools are available at the intended time. How are maintenance activities planned, controlled and monitored? Manual planning and assignment of work orders Rough system-supported preliminary planning with manual disposition Detailed system-supported detailed planning, which also takes over rescheduling in the event of unplanned deviations (e.g. loss of staff and resources) How would you currently assess the planning level of the maintenance organisation?Proportion of operations / activities that are proactively scheduled.Less than 25%25 - 50%50 - 75%Over 75%How are currently recurring tasks scheduled? Purely deadline-driven with planned start and end date Scheduled with dynamic prioritisation based on optimisation heuristics and algorithms How is the scheduling of recurring maintenance activities done? Maintenance dates are determined by the maintenance organisation Predefined time windows on the part of production must be adhered to Continuous coordination with other planning systems is required (e.g. machine occupancy). How detailed should procedural and work instructions be mapped? Organisational information is sufficient Detailed description of the tasks and work steps in the sense of instructions Documentation of checkpoints and tests Which causes of failure are frequently observed and occur approximately monthly? A quantitative assignment of faults to causes does not take place or is not documented. Wear of functional components Overload Environmental influences Malfunctions How are faults currently recorded and documented? Manually with the help of forms and logbooks Event reports are archived in an IT system on a unit- and system-specific basis The documentation takes place in an IT system with a form that is validated upon entry Where technically possible, incident reports are generated automatically How is the evaluation of disturbances carried out? An evaluation and discussion of the results with other areas takes place as required. The failure analysis is part of regular reporting and deviation analyses. A malfunction analysis is only carried out in the event of recurring malfunctions in the operating process Which infrastructure documents do you use in the context of maintenance? Floor plans and layouts of premises and facilities Site plans with additional maintenance-relevant information Documentation of the transport and material flow routes Machine and plant layouts How are maintenance activities reported back and documented? Overall feedback (completed/executed) Position-oriented Recording and documentation of individual measured values Which information and master data of maintenance objects are recorded with IT support? Structure BOMs Associated maintenance activities in the form of accompanying documents Associated maintenance activities are maintained in the form of individual master data records Do extensive maintenance tasks require interim documentation? Shift handovers Status logs Independent project planning How many people are employed in your maintenance organisation Less than 10 10 - 25 employees 25 - 50 employees more than 50 employees Further personnel resources in maintenance Maintenance tasks are carried out exclusively by dedicated employees Other functional areas (e.g. operating or cleaning staff) also take on maintenance tasks External service providers are also involved for recurring tasks Is human resource planning done on the basis of a skills matrix? Yes, the assignment of employees to maintenance tasks is done according to a qualification matrix No, a manual allocation is carried out based on empirical knowledge Do manufacturers take over fixed maintenance services? Remote monitoring Preventive maintenance measures with a fixed scope of services Complete takeover of maintenance for defined machines and systems What interfaces exist between maintenance planning and other systems? A separate planning system is used, with existing master data from existing systems being transferred via interfaces. Maintenance planning is integrated into a higher-level ERP or MES system A self-sufficient planning system is used Which ERP system do you use? We do not use an ERP system SAP ProAlpha Infor Other (please specify) Other ERP system Add Remove Which direct cost types have a significant order of magnitude for you and should be recorded separately and be able to be evaluated in relation to different cost units? Internal personnel costs Costs for external services Further training and qualification costs Spare parts costs Costs for operating resources Other (please specify) How detailed is the cost centre and cost unit accounting? Performance-oriented - cost unit is the maintenance order Object-oriented - cost object is the maintenance object Both performance and object oriented Which key figures are recorded for the purpose of maintenance control? Machine and plant availability Style life and utilisation Machine output Energy consumption Process and quality indicators of the goods produced Implementation times of maintenance measures Frequency distributions of disorders and causes Overall Equipment Effectiveness (OEE) More What is the control function of the collected key figures? Identification of deviations from the plan and intervention Monitoring the sustainability strategy Cost optimisation Basis for incentive systems More Budget planning - determination of the maintenance budget Planning is always based on the figures from the previous period, adjusted for special effects. On the basis of future requirements resulting from production planning Planning takes place with the inclusion of optimisation specifications What are the essential decision parameters? Process safety Direct acquisition costs Flexibility of production resources Life cycle costs Service offer of the manufacturers Form of financing Availability and performance guarantees Resource and energy consumption (not only from a cost perspective) Unit costs or costs/unit of output Circular economy and recycling E-mail(required)You will receive a detailed evaluation of your requirements and we will identify suitable systems. Your e-mail address will not be passed on. Consent(required) I agree to the privacy policy.Privacy policy