Table 5.

Key factors versus maintenance performance at various levels

Factors	Level 3 (100%) Advanced (predictive & proactive)	Level 2 (66.7%) Intermediate (preventive)	Level 1 (33.3%) Beginning (reactive)
Maintenance Effectiveness	Maintenance performance is very satisfactory where no improvement is warranted.	Maintenance program is effective but could still be improved.	Maintenance has significant room for improvement, or Preventive maintenance program is lacking/reactive maintenance
Maintenance Strategy	Employ predictive maintenance (PdM) strategy for sustainable improvement. All problems are analyzed and permanently solved. Reactive maintenance is minimized.	Use preventive maintenance (PM) as a main approach, usually age-based or cycle-based. Some reactive maintenance is required.	Rely heavily on reactive maintenance (RM), no equipment health information involved
Task Planning and Scheduling	More than 90 % of work that is planned is accomplished. Low overtime for maintenance activities (<15 %)	More than 50 % work planned accomplished. Relatively high overtime ( >15 %)	Less than 50 % work planned accomplished. High overtime ( >30 %)
Profitability	Significant cost savings due to failure reduction and life extension	Cost-effectiveness is satisfactory	Not cost-effective
Continuous improvement	Proactive maintenance. CBM or PHM applied, performance measurements are in place and effectively used	Have preventive maintenance in place with management involved in policy settings and reviews	Have no CBM or PHM. Low involvement of management. Reactive maintenance is very common
Maintenance Training (Human factors)	Educational plans are designed for each maintenance worker. A global R&D Team is in place that is responsible for developing and implementing prognostic and diagnostic techniques	Skilled staff normally qualified on a few machines. A small team is in place that is responsible for developing and implementing prognostic and diagnostic techniques	No training on how to use maintenance strategies. Lack of system to collect maintenance knowledge. No team that is responsible for developing and implementing prognostic and diagnostic techniques
Total productive performance (TPM)	Overall Equipment Effectiveness (OEE) is greater than 80 %	Overall Equipment Effectiveness (OEE) is between 50% and 80%	Overall Equipment Effectiveness (OEE) is less than 50%
Organizational Readiness	Leadership Involvement and strong R&D support	Lack of sufficient R&D support & leadership involvement	“Fire Fighting” approach