A key element to any organization’s success is having a maintenance department running at optimal effectiveness and efficiency. To achieve this, it is essential to have competent schedulers that can ensure the maintenance workforce is provided with the right information, tools, and materials. However, very few have been formally trained which leads to inefficiencies in both maintenance and operations. As a result, proficient work preparers with the proper knowledge and training are in high demand.

In this presentation from NFMT Remix, Andy Gager, CEO, AMG International Consulting introduces key performance indicators that highlight common inefficiencies within maintenance departments. For instance, maintenance operations tend to waste approximately a third of their budget, with 63 percent of maintenance tasks being self-induced issues. This concept, called "maintenance-induced maintenance," refers to situations where previous repairs or processes inadvertently create new problems. Additionally, nearly 50 percent of a technician's day is often spent on non-productive tasks, such as walking to and from job sites or looking for parts, rather than on actual maintenance work.

Gager emphasizes four core methods of maintenance strategies: preventive, predictive, run-to-failure, and proactive maintenance. Each strategy has a place, depending on the equipment and the consequences of failure. For instance, certain assets can be allowed to run until failure without major repercussions, like light bulbs, whereas critical equipment may require constant monitoring and proactive maintenance to avoid costly breakdowns.

Inventory management and supply chain control are also key aspects of effective maintenance. Carrying excessive inventory can inflate costs and waste resources. Organizations should assess the need for each part and optimize inventory levels, avoiding the common trap of simply expanding storage space to accommodate unnecessary parts.

Proper planning and scheduling can also lead to a three-to-fourfold return on effort, particularly in labor-intensive tasks. By structuring maintenance operations with clear priorities and appropriate staffing levels, organizations can achieve high standards without overburdening their resources. Successful maintenance isn’t the cheapest approach but rather the optimal one that balances cost with effectiveness and reliability.

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