981009SYQNA001DMCP1CONFIDENTIALThisreportissolelyfortheuseofclientpersonnel.Nopartofitmaybecirculated,quoted,orreproducedfordistributionoutsidetheclientorganisationwithoutpriorwrittenapprovalfromMcKinsey&Company.ThismaterialwasusedbyMcKinsey&Companyduringanoralpresentation;itisnotacompleterecordofthediscussion.DiscussiondocumentOctober1998KeyElementsofWorld-classMaintenance:FacilitySelfAssessment981009SYQNA001DMCP12KEYELEMENTSOFWORLD-CLASSMAINTENANCEThereare6keyelementsofworld-classmaintenance.Whileeachelementcanbeconsideredseparately,atrueworld-classmaintenanceorganisationwillcontainall6keyelementsOverallgoalsKeyelementsAchieveworld-classmaintenanceperformanceProblemdiagnosisandrepairexecutionMaximiseeffectivenessMaximiseefficiencyEquipmentstrategyOrganisationalcapabilitiesPlanningandschedulingInfrastructuresupportSystemsupport981009SYQNA001DMCP13KEYELEMENTSOFWORLD-CLASSMAINTENANCE:MAXIMISEEFFECTIVENESSOverallgoalsKeyelementsPrimarycomponentsAchieveworld-classmaintenanceperformanceMaximiseefficiencyProblemdiagnosisandrepairexecution•Gettingthejobfixedfastandfixedrightthefirsttimeattheroot-causelevelEquipmentstrategy•Executinglowtotal-costequipmentstrategiesfocusedonpreventingfailuresandeliminatingallpossibleequipmentdefectsOrganisationalcapabilities•Anorganisationwhichcommunicateswellcross-functionally,sharesaccountability,andcontinuouslybuildskeyskillsInfrastructuresupportPlanningandschedulingSystemsupportProblemcommunicationProblemroot-causeidentificationRepairplanningandexecutionMaintenancestrategylinkedwithequipmentcriticalityLife-cyclepurchasingstrategiesDesign-outengineeringServicingandpreventivemaintenanceOrganisationalstructurePerformanceethicSkillbuildingCross-functionalcommunicationsMaximiseeffectiveness981009SYQNA001DMCP14KEYELEMENTSOFWORLD-CLASSMAINTENANCE:MAXIMISEEFFICIENCYOverallgoalsKeyelementsPrimarycomponentsAchieveworld-classmaintenanceperformance•Equipmentavailability•MaintenancecostInfrastructuresupport•Providingtherightfacilities,materials,andotherresourcesforefficientmaintenanceexecutionPlanningandscheduling•Gettingtherightpeoplewiththerightinformation,skills,andresourcesattherighttimedoingtherightjobsSystemsupport•Providingtherightinformationinordertoexecutejobs,identifyroot-causeproblems,executeequipmentstrategiesandtrackperformanceMaximiseeffectivenessMaximiseefficiencyEquipmentstrategyProblemdiagnosisandrepairexecutionOrganisationalcapabilitiesJobplanningforroutineworkScheduledevelopmentandadherenceforroutineworkShutdownplanning,schedulingandexecutionPartsprocurementandissue(stores,ordering,availabilityandquality)Toolstorage,maintenance,issueContractormanagementComputersystemComputersystemtrainingEquipmenthistorystorage/retrieval981009SYQNA001DMCP15MAXIMISEEFFECTIVENESS:PROBLEMDIAGNOSISANDREPAIREXECUTIONComponentPoorAverageGoodWorld-classProblemcommunication•Nooperationsimprovementinproblemreporting•Operationsreportproblemswithminimaldescription•Operationsmakedetailedproblemdescriptionsbeforerepairs•Operationsmakedetailedproblemdescriptionsbeforerepairsandcommunicatewithmaintenanceduringandafterrepairs•Craftsmenreceivesketchyandincompletejobinstructions•Craftsmenreceivecompletedescriptionoftaskswithlittlesupportingdetail•Craftsmenreceivecompletedescriptionoftasksandparts•Craftsmenreceivecompleteinformationandworkorderdetails(es...
