Plant maintenance audits are powerful assessment tools that can help your company to utilize resources more efficiently and achieve specific objectives such as cutting energy use or reducing overtime expenses.
Maintenance audits originated a few decades ago and have steadily grown in popularity. They find use today in diverse industries ranging from manufacturing and papermaking to steel production and energy processing.
The auditing process can take anywhere from a half-day to a week or more to complete. Although audits come in many forms, they can generally be classified in two categories: plant-wide general audits and small-scale targeted audits. Plant-wide audits provide a detailed overview of a facility’s maintenance strategies, organization, and activities, while targeted audits hone in on specific maintenance issues such as lubricant use or rejected parts.
General audits
General audits are usually conducted by consulting firms or other parties skilled in auditing methods. The audit typically starts with a mapping of a facility’s operational processes and maintenance assets. Diagrams are produced showing the plant’s organizational structure and layout, including locations of maintenance workshops and storerooms. Charts detail the shift rosters and work functions of maintenance groups such as pipefitters and electricians.
The audit also outlines the facility’s schedule of planned maintenance on major equipment. This includes the frequency of expected maintenance on key machines, which can range from monthly to every three or six months. The planned downtime required for each procedure is also listed.
After the mapping is completed, the auditing team analyzes the maintenance department’s overall effectiveness and compares it with that of similar facilities and with widely accepted industry benchmarks. Data on downtime events, machine availability and overtime hours are examined. Finally, a report is issued summarizing the audit’s findings and including recommendations for improvement.
Telltale signs
Your facility might benefit from a maintenance audit if it has recently expanded in size or been restructured. Such changes can disrupt work flows and affect delivery of maintenance services.
