Bluefield has conducted several maintenance execution audits. We continually find the basic capability, required to deliver reliable equipment, to be missing. That is, the ability to perform a preventative or predictive maintenance task or inspection, adequately maintain the condition of the equipment to prevent the onset of the failure mode or, identify defects and have them corrected in a scheduled fashion prior to becoming a breakdown.
The key reasons that this problem exists are as follows:
The quality of the preventative or predictive work is not adequate and not the focus of management
Raising of subsequent work identified in the inspections is not done consistently
Work orders are not closed out correctly so the list of open work is out of control and the work priorities are hidden
The good news is that these problems are simple to correct (read how here) and by improving this basic element of reliability, immediate improvements will follow.