Asset Maintenance Requirements (AMR) – Sub Category 5.0
DISCOVER – What maintenance data is essential?
Identify the maintenance data required to ensure efficient and effective operations, including maintenance history, asset condition, performance trends, task frequencies, and operational constraints. Use operational data, records, and industry good practice to shape maintenance strategies.
DEFINE – How will maintenance tasks and schedules be structured?
Develop comprehensive maintenance schedules and procedures aligned with asset criticality and operational demands, ensuring structured tasks, frequencies, and work instructions that support asset uptime.
DESIGN – What tools manage maintenance tasks?
Deploy advanced maintenance management systems such as Computerised Maintenance Management Systems (CMMS) to plan, schedule, track, and close out maintenance activities and capture performance data.
DEPLOY – How will maintenance data be maintained?
Implement feedback loops that feed maintenance outcomes and performance measures back into planning and optimisation processes so that strategies, intervals, and task content are continually improved.
6W1H Analysis
Maintenance Planners and Technicians manage histories, task logs, and performance metrics stored in a CMMS. Records are updated after each job and during performance reviews. The purpose is to optimise strategies, minimise downtime, and extend asset life. Automation and analytics tools support data capture and insight generation. Costs include CMMS implementation, training, and ongoing support.
DISCOVER
Identify the strategic need for an integrated maintenance plan across all asset categories and locations.
DEFINE
Outline governance, processes, and standards that will control maintenance planning and implementation so that plans align with organisational objectives and risk appetite.
DESIGN
Develop detailed implementation strategies and schedules that define responsibilities, resources, timeframes, and key milestones.
DEPLOY
Execute the maintenance plan, monitor its effectiveness, and adjust based on performance data, stakeholder feedback, and review outcomes.
6W1H Analysis
Project Managers and Maintenance Coordinators oversee implementation across all departments. Plans are embedded in EAM/CMMS systems and reviewed during annual planning cycles. The purpose is lifecycle value, reliability, and consistent execution. Costs relate to planning effort, system support, and periodic reviews.
DISCOVER
Determine potential failure modes for each asset type and assess their consequences on safety, environment, production, and cost.
DEFINE
Standardise the FMEA process, including risk criteria, scoring, and rules for prioritising failure modes and mitigation actions.
DESIGN
Integrate FMEA outputs into maintenance plans, risk registers, and improvement programs so that high-risk issues drive preventive and predictive tasks.
DEPLOY
Conduct FMEA reviews at asset acquisition, during lifecycle reviews, and following significant failures, and feed findings into maintenance and risk management processes.
6W1H Analysis
Reliability Engineers, Maintenance Engineers, and Risk teams run FMEAs. Results are stored in risk and maintenance systems and reviewed periodically. The purpose is proactive risk reduction and reliability improvement. Costs include workshops, analysis time, and tool licences, offset by reduced unplanned downtime and incidents.
DISCOVER
Evaluate asset criticality and risk profiles to determine which assets require enhanced inspection and monitoring.
DEFINE
Establish criteria for RBI including inspection frequency, techniques, documentation requirements, and acceptance criteria.
DESIGN
Develop inspection plans and schedules aligned with risk assessment outcomes, available resources, and statutory requirements.
DEPLOY
Perform inspections as planned, update risk profiles based on findings, and adjust maintenance and inspection strategies where risk conditions change.
6W1H Analysis
Inspection Teams, Maintenance Engineers, and Risk Professionals manage RBI programs. Data is stored in inspection and maintenance systems and reviewed according to risk-based intervals. Purpose is to focus effort on high-risk equipment and prevent failures. Costs include training, inspection methods, and specialised tools.
DISCOVER
Identify assets that will benefit from CBM by analysing duty, failure consequences, and potential value from condition-based interventions.
DEFINE
Define monitored parameters and threshold limits that will trigger maintenance actions or further investigation.
DESIGN
Implement sensors, monitoring technologies, and analytics that continuously assess condition and provide actionable insights.
DEPLOY
Use real-time data to plan and schedule work based on actual equipment condition, reducing failures, avoiding unnecessary tasks, and extending asset life.
6W1H Analysis
Maintenance, Reliability, and Operations teams manage CBM systems. Data is stored in monitoring platforms and CMMS. Monitoring is continuous. Purpose is to move from time-based to condition-based interventions. Costs include instrumentation, connectivity, analytics tools, and training.
DISCOVER
Assess current and future skill requirements needed to support advanced maintenance and reliability strategies.
DEFINE
Define skill profiles, competency standards, and staffing levels required to deliver safe and effective maintenance.
DESIGN
Create training programs, certification pathways, and development plans that build and sustain required skills within the workforce.
DEPLOY
Evaluate staff performance regularly, deliver ongoing training, and adjust workforce planning as technologies and maintenance strategies evolve.
6W1H Analysis
HR, Training Managers, and Maintenance Supervisors manage skills data in HR and learning systems. Reviews occur at recruitment, periodically, and after major strategy changes. Purpose is a competent workforce that supports asset reliability. Costs include assessments, training delivery, and certification.
DISCOVER
Analyse maintenance activities and consumption history to determine optimal stocking levels for parts and materials.
DEFINE
Define inventory management practices that balance availability of critical components with working capital and holding cost constraints.
DESIGN
Configure inventory control systems to track usage, forecast demand, and automate replenishment based on lead times and risk.
DEPLOY
Review inventory performance regularly, adjust stocking policies based on usage trends and feedback from maintenance teams, and manage obsolete stock.
6W1H Analysis
Inventory Managers and Maintenance Planners manage MRO data in inventory and procurement systems. Management is continuous with scheduled reviews. Purpose is high availability with minimal cost. Costs include system licences, storage, and working capital.
DISCOVER
Identify maintenance activities that can be outsourced to improve efficiency, flexibility, and access to specialist skills.
DEFINE
Establish selection criteria, performance measures, and management protocols for external contractors and service providers.
DESIGN
Negotiate contracts that align with maintenance objectives, defining clear scopes, KPIs, safety expectations, and compliance obligations.
DEPLOY
Oversee contractor performance, integrate their work into maintenance plans, and conduct regular reviews to confirm value and compliance.
6W1H Analysis
Maintenance, Procurement, and Contract Owners manage contracts and performance information in contract and CMMS systems. Reviews are carried out at agreed intervals. Purpose is to supplement in-house capability and manage cost and risk. Costs are contract fees and management effort.
DISCOVER
Review maintenance needs, utilisation, and risk for all fixed plant and mobile equipment fleets.
DEFINE
Define maintenance protocols, inspection regimes, and performance standards to maximise reliability, safety, and productivity.
DESIGN
Implement systems that schedule, monitor, and record maintenance activities for plant and mobile equipment, including defect logging and utilisation tracking.
DEPLOY
Execute maintenance in line with schedules, monitor performance, and adjust strategies based on usage and failure patterns.
6W1H Analysis
Maintenance Engineers, Planners, and Operators collaborate using CMMS and fleet systems. Activities are continuous with formal reviews. Purpose is to minimise downtime and extend equipment life. Costs include maintenance labour, parts, and system support.
DISCOVER
Forecast financial requirements for maintaining assets across their lifecycle, including operating and capital needs.
DEFINE
Define budgeting procedures that link maintenance strategies, risk, and performance targets to funding requirements.
DESIGN
Develop financial models and planning tools that connect maintenance plans and work programs with budget allocations and long-term forecasts.
DEPLOY
Monitor budget performance, adjust plans for actual spend and emerging risks, and keep financial resources aligned with strategic maintenance needs.
6W1H Analysis
Financial Planners, Maintenance Managers, and Analysts manage budgets in financial systems. Planning is annual with periodic reviews. Purpose is adequate funding and cost efficiency. Costs include modelling tools, analysis effort, and governance.
DISCOVER
Identify KPIs that best measure the effectiveness and efficiency of maintenance activities.
DEFINE
Define a consolidated set of KPIs that reflect strategic maintenance goals and operational performance requirements.
DESIGN
Create dashboards and reporting mechanisms that update maintenance performance against defined KPIs using near-real-time data.
DEPLOY
Use KPI results to guide strategy changes, improvement initiatives, and resource allocation decisions.
6W1H Analysis
Maintenance and Operations Managers with Performance Analysts maintain KPI frameworks in performance systems. Data is updated continuously and reviewed at regular intervals. Purpose is transparency, accountability, and continual improvement. Costs include analytics tools and analysis effort.
DISCOVER
Identify common and recurring defects that impact asset performance, reliability, and cost.
DEFINE
Establish systematic processes for capturing, analysing, and eliminating defects, including roles, workflows, and escalation rules.
DESIGN
Implement continuous improvement programs that use defect data to refine maintenance practices and inform design modifications and standards.
DEPLOY
Analyse defect trends on a routine basis, implement corrective and preventive actions, and track the effectiveness of elimination efforts.
6W1H Analysis
Maintenance Engineers, Reliability Engineers, and Quality teams manage defect processes using CMMS and quality systems. Reviews are ongoing. Purpose is to remove chronic failures, reduce cost, and lift reliability. Costs include investigation time and corrective work, offset by improved performance and fewer repeat issues.