【正文】 981009SYQNA001DMCP1 CONFIDENTIAL This report is solely for the use of client personnel. No part of it may be circulated, quoted, or reproduced for distribution outside the client anisation without prior written approval from McKinsey amp。 Company. This material was used by McKinsey amp。 Company during an oral presentation。 it is not a plete record of the discussion. Discussion document October 1998 Key Elements of Worldclass Maintenance: Facility Self Assessment 981009SYQNA001DMCP1 1 KEY ELEMENTS OF WORLDCLASS MAINTENANCE There are 6 key elements of worldclass maintenance. While each element can be considered separately, a true worldclass maintenance anisation will contain all 6 key elements Overall goals Key elements Achieve worldclass maintenance performance Problem diagnosis and repair execution Maximise effectiveness Maximise efficiency Equipment strategy Organisational capabilities Planning and scheduling Infrastructure support System support 981009SYQNA001DMCP1 2 KEY ELEMENTS OF WORLDCLASS MAINTENANCE: MAXIMISE EFFECTIVENESS Overall goals Key elements Primary ponents Achieve worldclass maintenance performance Maximise efficiency Problem diagnosis and repair execution ? Getting the job fixed fast and fixed right the first time at the rootcause level Equipment strategy ? Executing low totalcost equipment strategies focused on preventing failures and eliminating all possible equipment defects Organisational capabilities ? An anisation which municates well crossfunctionally, shares accountability, and continuously builds key skills Infrastructure support Planning and scheduling System support Problem munication Problem rootcause identification Repair planning and execution Maintenance strategy linked with equipment criticality Lifecycle purchasing strategies Designout engineering Servicing and preventive maintenance Organisational structure Performance ethic Skill building Crossfunctional munications Maximise effectiveness 981009SYQNA001DMCP1 3 KEY ELEMENTS OF WORLDCLASS MAINTENANCE: MAXIMISE EFFICIENCY Overall goals Key elements Primary ponents Achieve worldclass maintenance performance ? Equipment availability ? Maintenance cost Infrastructure support ? Providing the right facilities, materials, and other resources for efficient maintenance execution Planning and scheduling ? Getting the right people with the right information, skills, and resources at the right time doing the right jobs System support ? Providing the right information in order to execute jobs, identify rootcause problems, execute equipment strategies and track performance Maximise effectiveness Maximise efficiency Equipment strategy Problem diagnosis and repair execution Organisational capabilities Job planning for routine work Schedule development and adherence for routine work Shutdown planning, scheduling and execution Parts procurement and issue (stores, ordering, availability and quality) Tool storage, maintenance, issue Contractor management Computer system Computer system training Equipment history storage/retrieval 981009SYQNA001DMCP1 4 MAXIMISE EFFECTIVENESS: PROBLEM DIAGNOSIS AND REPAIR EXECUTION Component Poor Average Good Worldclass Problem munication ? No operations improvement in problem reporting ? Operations report problems with minimal description ? Operations make detailed problem descriptions before repairs ? Operations make detailed problem descriptions before repairs and municate with maintenance during and after repairs ? Craftsmen receive sketchy and inplete job instructions ? Craftsmen receive plete description of tasks with little supporting detail ? Craftsmen receive plete description of tasks and parts ? Craftsmen receive plete information and work order details (estimated labour hours, tasks, materials and equipment history) Rootcause identification ? No rootcause analysis and repair work is often repeated ? Informal/ad hoc analysis on repeat problems and equipment ? Rootcause analysis is done on major equipment ? Equipment is fixed right the first time based on rootcause analysis ? Maintenance has no engineering support ? Maintenance has occasional engineering support ? Engineers do most project work and some rootcause analysis ? Engineers fully support rootcause analysis Repair planning and execution ? Operators do not participate in maintenance repairs or adjustments ? Operators assist maintenance on some tasks and perform minor adjustments/repairs only in an emergency ? Operators assist maintenance on major tasks and do some minor adjustments and repairs but are not trained ? Operators are trained to assist maintenance on major tasks and to execute simple routine equipment adjustments and repairs ? Craftsmen only do assigned tasks ? Craftsmen look at problem and plan on the spot ? Craftsmen know scheduled jobs and participate in planning ? Craftsmen plan simple maintenance work and participate in planning major tasks ? Crews most