🔧 Maintenance & Reliability Assessment

Summary Maturity Model Evaluation Tool

📋 How to Use This Assessment

  1. Fill in your organization information above
  2. Navigate through each category tab
  3. Review the maturity level criteria for each element
  4. Enter your score (1-5) based on your current state
  5. Provide evidence and comments to support your assessment
  6. Review the summary dashboard to see your overall maturity
  7. Click "Export to Excel" to save your completed assessment

Overall Maturity Score

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Complete assessment to see results

📊 Category Maturity Summary

Visual representation of current maturity levels across all assessment categories

Maturity Scale
Red (1) → Yellow (3) → Green (5)
Current Score
Your organization's position

Maturity Level Definitions

Level 1
Initial/Ad Hoc
Reactive, inconsistent processes
Level 2
Managed
Basic processes documented and followed
Level 3
Defined
Standardized processes across organization
Level 4
Optimized
Data-driven continuous improvement
Level 5
Leading
Industry-leading practices, innovation

1. Reliability Program

Category Score: -
a. Maintenance Program Design
Level Criteria Description
1 Reactive maintenance only, minimal documentation
2 Basic PM program exists with some documentation
3 Robust PM program with RCM analysis, documented procedures
4 PM procedures optimized based on failure analysis and condition monitoring
5 Best-in-class program with continuous optimization, predictive technologies deployed
b. Condition Monitoring
Level Criteria Description
1 No formal condition monitoring program
2 Basic condition monitoring for critical equipment
3 Comprehensive monitoring program with documented procedures
4 Advanced diagnostics including vibration, thermography, oil analysis
5 Predictive analytics and real-time monitoring with automated alerts
c. Procedures & Standards
Level Criteria Description
1 Minimal or no documented procedures
2 Basic procedures for critical tasks
3 Comprehensive procedures for all major tasks, version controlled
4 Procedures optimized based on failure analysis, regularly reviewed
5 Industry-leading procedures with continuous improvement process
d. Criticality Analysis
Level Criteria Description
1 No formal criticality ranking
2 Basic criticality assessment for major equipment
3 Comprehensive criticality analysis using defined methodology
4 Risk-based criticality with regular updates and optimization
5 Advanced risk modeling with real-time criticality updates

2. Maintenance Management Process

Category Score: -
a. Process Documentation
Level Criteria Description
1 No formal maintenance management process
2 Basic processes documented for key activities
3 Comprehensive process documentation, roles defined
4 Processes optimized and integrated with business systems
5 World-class processes with continuous improvement culture
b. Planning & Scheduling
Level Criteria Description
1 Reactive, minimal planning
2 Basic scheduling for PM activities
3 Comprehensive planning/scheduling with weekly schedules
4 Optimized scheduling with resource leveling and backlog management
5 Advanced planning with predictive scheduling and optimization
c. Performance Metrics
Level Criteria Description
1 Minimal performance tracking (e.g., downtime hours, PM completion)
2 High-level KPIs are tracked (e.g., OEE, bad actor, PM completion, # of work orders in backlog)
3 Comprehensive KPIs are tracked (e.g., OEE, MTBF, MTTR, % proactive/reactive, maintenance cost as % of RAV, schedule compliance, on-time PM completion, backlog)
4 KPIs are regularly reviewed with improvement targets and regular problem solving focuses on top equipment maintenance downtime drivers
5 Deep dive reliability KPIs are measured and critical system reliability growth is regularly reviewed

3. Work Management

Category Score: -
a. Work Order Management
LevelCriteria Description
1No formal work order system
2Basic work order system with limited tracking
3Comprehensive CMMS with full work order lifecycle
4Optimized work orders with job plans and labor tracking
5Integrated system with mobile access and real-time updates
b. Backlog Management
LevelCriteria Description
1No backlog management
2Awareness of backlog but minimal management
3Formal backlog review and prioritization process
4Optimized backlog with risk-based prioritization
5Predictive backlog management with capacity planning
c. Shutdown Management
LevelCriteria Description
1Reactive shutdown approach
2Basic shutdown planning
3Comprehensive shutdown planning with critical path
4Optimized shutdowns with lessons learned and continuous improvement
5Best-in-class shutdown execution with predictive planning
d. Contractor Management
LevelCriteria Description
1Ad hoc contractor usage
2Basic contractor agreements and oversight
3Formal contractor management with performance tracking
4Strategic contractor partnerships with KPIs
5Integrated contractor management with shared risk/reward

4. Spares Management

Category Score: -
a. Inventory Management
LevelCriteria Description
1No formal inventory system, reactive purchasing
2Basic inventory tracking with minimal controls
3Comprehensive inventory system with min/max levels
4Optimized inventory with ABC analysis and turnover targets
5Predictive inventory management with vendor integration
b. Criticality & Optimization
LevelCriteria Description
1No spare parts criticality assessment
2Basic criticality for major components
3Comprehensive criticality with risk-based stocking
4Optimized spares using failure analysis and reliability data
5Advanced analytics with predictive modeling for spare parts
c. Procurement & Logistics
LevelCriteria Description
1Reactive, emergency procurement
2Basic procurement process with supplier relationships
3Strategic procurement with contracted vendors
4Optimized procurement with vendor-managed inventory
5Integrated supply chain with real-time visibility

5. Training & Competency

Category Score: -
a. Training Programs
LevelCriteria Description
1Minimal training, on-the-job only
2Basic safety and equipment training
3Comprehensive training programs with documented curriculum
4Competency-based training with certification
5World-class training academy with continuous learning culture
b. Competency Management
LevelCriteria Description
1No formal competency assessment
2Basic skill tracking
3Formal competency matrix with defined skill levels
4Comprehensive competency management with career paths
5Predictive competency planning with succession management
c. Knowledge Management
LevelCriteria Description
1Knowledge resides with individuals
2Basic documentation and procedures
3Centralized knowledge base with lessons learned
4Comprehensive knowledge management system
5AI-enabled knowledge system with expert networks

6. Digital Tools & Technology

Category Score: -
a. CMMS/EAM System
LevelCriteria Description
1Paper-based or spreadsheet tracking
2Basic CMMS with limited functionality
3Comprehensive CMMS with full modules implemented
4Optimized CMMS with mobile access and integrations
5Cloud-based EAM with AI/ML capabilities and IoT integration
b. Condition Monitoring Tools
LevelCriteria Description
1No digital condition monitoring
2Basic handheld devices for key equipment
3Comprehensive monitoring with automated data collection
4Advanced analytics and predictive diagnostics
5Real-time monitoring with AI-driven predictions
c. Data Analytics
LevelCriteria Description
1No data analytics capability
2Basic reporting from CMMS
3Structured KPI dashboards and trending
4Advanced analytics with predictive modeling
5AI/ML-driven insights with prescriptive recommendations
d. Digital Transformation
LevelCriteria Description
1No digital transformation strategy
2Awareness of digital opportunities
3Digital roadmap with pilot projects
4Scaled digital solutions (mobile, IoT, AR/VR)
5Industry 4.0 leader with autonomous maintenance capabilities
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