XNET Technical Services, LLC
 
Preliminary Maintenance Analysis
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Preliminary Maintenance Analysis
 
Job Opportunity with XNET
 
Name:
Title:
Position:
Company Name:
Address:
Telephone:
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Maintenance and Organization Culture:
 

1.

 How is maintenance organization structured?
  Top heavy (lots of managers/supervisors, few workers)
Flat (No apparent persons in charge managing work)
 Lean (Few managers/supervisors, lots of workers)
 
2. Which best describes relationship between Maintenance Organization and Operations?
  Operations dictates maintenance priorities
Maintenance controls work scheduling and priorities
Operations and maintenance work together in setting schedules and job priorities
 
3. How are annual maintenance tasks prioritized?
  Top Priority when problems occur
Always secondary to process maintenance
Seasonally, weather permitting, according to schedule
 
4. Rate Maintenance management recognition in company?
  Maintenance has a voice at the highest level
Maintenance is a necessary evil, slowing down production
Maintenance managers are secondary to production managers
 
5. Which best describes company's Open Communication policy?
  Only a few key people make decisions
Most people work siloed in private groups, low communication
Communication is open and free on all levels
Organization and Administration:
 
1. Describe formal documentation of maintenance organization structure?
  An organization chart and basic job descriptions exist
No organization chart exists; workers are expected to flow to the work as needed
 
2. How are workers required to keep up their skills?
  A formal recertification program exists
Supervisors keep close eye on worker skill level efficiency
No formal updating of skills are required, on job training suffices
 
3. What kind of time-keeping system is used for pay and work?
  One system is used to record wrench time, non-wrench time and pay hours
Two systems are used; one to record work time and another to record pay hours
 
4. How are work Backlogs standards used?
  Backlog standards are not used
Backlog standards are established to control inhouse overtime
Backlog standards are established to control outside contract work
Backlog standards are used to control overtime and contract work
Work and Authorization Control:
 
1. Describe work order flow process?
  Work order flow process is consistent, clear and understood by all
Work order flow is determined depending on the type of work order
There is not one work order flow process, work is done as needed
 
2. How are work orders screened?
  Work orders are reviewed after actual work starts
Work orders are screened by area planners prior to initializing workflow process
Work orders come in through a call center and are distributed to appropriate supervisor
 
3. What type of customer service is rendered to those writing work orders
  Originators of work orders are contacted within a specified time frame from work order submission
    Work orders can only be written by a selected group or workers; who actually follow-up work order schedule
    Originators submitwork orders through supervisors who screen and prioritize work
 
4. How are work order prioritized?
  Depending on safety impact
Based on impact tocritical process equipment
Safety first, then impact on critical process equipment
Budget and Cost Control:
 
1. How is the Maintenance budget allocated?
  Maintenance budget is controlled by one person
Budget responsibilities are distributed among maintenance staff
Maintenance budget is controlled by Operations/Production
 
2. Describe how work order estimated costs are derived?
  Labor and material costs are formally tracked
Labor and material costs are not tracked formally
Labor and material costs are rolled-up for the department monthly
 
3. Who is responsible for project and work order cost overruns?
  Planners and Scheduler are responsible for project and work order cost
Maintenance Manager is responsible for all costs
Maintenance costs are absorbed into production cost
Maintenance Planning and Scheduling:
 
1. Which best describes how work orders are reviewed and approved?
    Originator's supervisor reviews and approves work order
    Originator's supervisor reviews initially; then other groups including engineering, operations, safety and environment review, as required
    There is no formal review process
 
2. A clear Scope of Work, with expected deliverables, is part of every major project?
  True
False
 
3. Daily work is planned for each craft at least one day in advance?
  True
False
Maintenance Storeroom:
 
1. Inventory accuracy is regularly measured to be about
 

95%
100%
90%
Don't Know

 
2. How would you describe the task of looking for parts?
  Easy (indexed illustrated parts catalogs are used)
Moderate (storeroom clerk has a good memory)
Difficult (parts are seldom available)
 
3. Which description best explains how Warehouse inventory levelsare managed?
  Warehouse inventories are about right
Warehouse inventories are too high
Warehouse inventories are too low
 
4. Concerning the software used to manage storeroom inventories, which statement is most correct?
  Supply-chain management software is used to reduce inventory costs
Warehouse inventory costs are shared with other sites through integrated software
No formal inventory software is used
Preventive and Predictive Maintenance:
 
1. Who is responsible for Preventive and Predictive Maintenance programs?
  Engineering
Maintenance Management staff
Technicians
Administrative Assistance
 
2. All critical equipment is reviewed for Preventive Maintenance services?
  True
False
Not sure
 
3. Which company benchmarks assess operation and control of maintenance equipment?
  Maintenance cost to replacement asset value
Percentage of planned maintenance work orders
Percentage of preventive maintenance work orders
All the above
Lubrication Program:
 
1. Which best describes Lubrication Program?
    A formal lubrication and analysis program is in place
    No formal program exists; lubrication is done as needed
    Lubrication is done during routine maintenance
    Lubrication routes are linked to work orders and performed, as needed, during work order
Overall Equipment Effectiveness (OEE):
 
1. Which measurement is part of OEE critical equipment program?
  Availability
Performance
Quality
All the above
 
2. How is OEE administered?
  Improvement teams are identified to improve OEE
Critical equipment defects are formally investigated
Documentation is used to monitor quality issues
All the above
Operator-Based Maintenance:
 
1. Operators are clearly designated as owners of equipment?
  True
False
Not sure
 
2. What role do Operators play in performing some maintenance tasks?
    Operators are designated to perform certain maintenance tasks such as lubrication and resetting equipment
    Operators do not perform maintenance tasks
    Operators focus on production only
 
3. Which statement best describes relationship between Operations and Maintenance?
  They are in agreement on work schedules and priority of work orders
There is little or no agreement
Engineering Support:
 
1. Which statement best describes relationship between Engineering and Maintenance?
    Engineering and Maintenance work seamlessly to make sure designs and project specifications have built-in reliability
    Engineering and Maintenance are two totally separate departments
 
2. How are engineering drawings and technical documentation handled?
  Engineering controls drawings and documentation
Maintenance controls O&M documentation after project are completed
Responsibility for documentation and engineering drawings is centralized and shared
 
3. Describe handling of spare parts
    A systematic approach is available for handling spare parts and equipment specifications
    There seems to always be a scramble to find spare parts
    Supply vendor usually identifies spare parts
 
4. Which statement best describes how capital projects are handled?
  Engineering manages all capital project work using outside labor
Capital projects are reviewed to see if inside labor can handle
There is much disagreement on who should perform capital project work
Safety Housekeeping and Regulatory Compliance:
 
1. Safety and good housekeeping are treated as serious matters, with consequences if not adhered to?
  True
 
2. Surprise safety audits and walk-through's are carried out as needed?
  True
False
Craft Skills Development:
 
1. Training needs are developed with real input from the craft personnel?
  True
False
 
2. Job descriptions and skill levels for all required craft positions have been identified and written for the work at hand?
  True
False
 
3. A program to periodically review job knowledge and skill level is in place to parallel changes in technology.
  True
False
Maintenance Performance Measurement:
 
1. An organized system is developed for measuring overall maintenance performance?
  True
False
 
2. A dedicated team of responsible managers and supervisors are designated to measure planning, scheduling and preventive maintenance performance results?
  True
False
Maintenance Supervisor/Leadership:
 
1. Supervisors have real authority including input on hiring and firing of craft personnel?
  True
False
 
2. How would you describe Maintenance Supervision Leadership?
  Supervisors are delegated responsibility with authority
Supervisors are delegated responsibility without authority
 
3. Supervisors support management planning strategies?
  Apparently
Not Really
Computerized Maintenance Management Systems (CMMS):
 
1. Describe the extent to which craft personnel are involved with CMMS implementation?
  Very little
Lots of involvement
Some
 
2. Describe data collection method for input into CMMS?
  Use accurate set of drawings to extract data
Use legacy data and migration method
Both a and b
Enter each record manually
 
3. What type of architectural design is in use for CMMS?
 

Client/Server
Web-based
Desk top stand alone
Maintenance Facilities, Equipment and Tools:
 
1. How would you describe maintenance shops?
  Well lighted, clean and properly ventilated; Labels in place
Sufficient distances from where most of the work is performed
Both a and b
None of the above
 
2. State Managements involvement in making sure the best and safest technology is available to optimize work?
    Management is actively involved and all jobs are performed with full access to necessary personal protective equipment and safety systems
    Management simply passes directives from upper management; not actively involved
 
3. Which statement best describes how tools are maintained?
    Standard tools are readily available and properly maintained through the use of a tested and proven system
    Tools are available but are checked only if, obvious maintenance is needed
    Each craftsman provides his own tools and is responsible for tool safety
    No formal maintenance tools program exists
Continuous Maintenance Improvement:
 
1. Maintenance Improvement Plans are best described as:
  Tied to clearly identifiable management strategies
Seldom implemented without upper management approval
Difficult to implement because everyone is so busy
 
2. Have you developed a leadership team with members from management, supervisors and key craft personnel?
  Yes
No
 
3. Teams with charters exist to address the following key maintenance business areas:
  Maintenance Management
Capital Information Management
Document Management (including CAD drawings)
Any combination of a, b, and c
No formal charters exist
 
4. Do you have a formal communications team to publish daily news about changes, site activities, recognitions, suggestions, new approaches and local business activities?
  Yes
No
 
  Other Info: