HOW MAINTENANCE WILL

REVOLUTIONIZE THE WORLD

Ryan Chan and Caitlyn Young

A book by
 1

INTRODUCTION

“ The world we have created is a product of our thinking;

it cannot be changed without changing our thinking.
- Albert Einstein
”
If we look at the maintenance hero’s journey, the metaphorical compass always
appears to point north – following the path of technology.

Just a few short years ago, maintenance was done by hand and recorded
correspondingly. Manufacturing plants would commonly wait until their equipment
failed before making repairs. The maintenance hero was the worker who got there
quickly and fire fought efficiently. They were the techs who stayed late, missing
dinner with their families, scouring cabinets of paper files for insight into why
equipment broke down in the first place. Their communication was done via a
confusing hodge podge of platforms: email, hand-written notes, and phone calls, but
they did it without complaint for the good of the business. Maintenance techs were
heroes for how quickly they reacted after an asset had broken down, and for the
deep wells of facility knowledge that lived in their brains alone. Historical knowledge
of a facility, its tips and tricks to get all of its assets working perfectly in sync, all left
when technicians transitioned or retired.

Today, equipment sensors alert workers when repairs are needed. Maintenance
heroes are commended for being quick, but today’s quick is at the first sign of
irregularity. The same workers who were praised for triaging in the past can snap
pictures of problems on-site, annotate and submit maintenance requests –
seamlessly updating all stakeholders live via their phones with one message. And
they’re celebrated for it. Reporting dashboards can pull up a full history of an asset’s
lifecycle with just a few keystrokes, and the maintenance heroes are the ones that
ensure the right inputs are exactly where they need to be so everyone can know
what they know. Nothing is secret and they make sure of it. From this digitized
knowledge, new maintenance workers receive full, automatic templated instructions
on their very first day. In the current world, there are more heroes than ever before,
and they all get to go home earlier to their families.

In the near future, we still see the metaphorical compass pointing our industry
towards further innovation. Workers will be able to utilize artificial intelligence (AI)
and predictive analytics to prevent most mechanical breakdowns from happening in
the first place. Driverless cars will own the road and robots will handle 90% of the
manual work that is done in facilities like fulfillment centers to manage inventory and
process orders.

If this inevitable evolution makes you fear for the maintenance hero’s demise, you’re
not alone. Dozens of headlines crowd news sites each day on how AI technology will
completely take over the workforce – leaving maintenance

Introduction 3
workers unemployed and resourceless. They paint a world where maintenance
tech’s traditional functions and contributions become obscure. The truth is, this
fear is not baseless. Indeed, your job in maintenance will inevitably be affected
by the ongoing automation of tasks and digitization of information – perhaps so
affected as to make your current role redundant.

The good news is, if the arc of history is any indication, you’ll find yourself out of a
job, and into an improved one. Most likely a better, higher paying and safer one
at that.

The trend towards automation has always been: destroy some existing jobs ->
modify most -> create tons of new jobs. It is, and always has been, a source of
fear for many, and an exciting launching pad for most.

Take the Luddites, English workers who smashed textile machines in the 19th
century out of fear of being displaced from their roles in the textile industry. Or
how when Johann Gutenberg introduced the printing press in the 15th century,
the scribes of Paris went on strike in fear that the mass production of materials
would mean the extinction of artistically-styled hand-scribed work. Or in 1964,
when scholars sent the “Triple Revolution Report” to President Lyndon Johnson
warning that industrial automation would leave millions unemployed. “The nation
will be thrown into unprecedented economic and social disorder,” the group
warned in their letter to the President.1 The Luddites, Parisian scribes and the
authors of the Triple Revolution Report were partly right – among the effects of
automation was the dissolution of jobs. Yet, these jobs ranged from the simple
and mundane to the highly dangerous, and new opportunities quickly arose. The
feared complete upheavals did not occur. Time and time again, “history shows
that the economy has consistently adjusted to advancing technology by creating
new employment opportunities and that these new jobs often require more skills
and pay higher wages.”2

There is no doubt that the job market in maintenance will look a lot different 10
years from now, just as it looks much different today than it did 10, 50, 100 years
ago. New technologies are evolving the workforce and changing the
maintenance hero’s job description, not replacing it.

Change is enabled by humans. It harnesses our existing knowledge, relies on our

ongoing input to course correct and our creativity to think of the NEXT change to
make the world better, safer, or more convenient. For automation to benefit the

Introduction 4
maintenance industry, this change will rely on you, the maintenance worker, to
be its shepherd. “Computers and digital devices are doing for mental power
what steam did for muscle power.”(3) Why fear this shift, when you can be at the
head of it, steering the maintenance industry into revolutionary new levels of
safety and profit?

In this book, we will explore how you can get ahead of the curve of technology,
playing an active role in your business today and in the years to come. In each
section of this guide, you’ll find real, tangible step-by-step instructions on how to
better your business using the tools and resources available to you today. We’ll
then discuss actions you can take to stay ahead of the technological
transformations that will rock our industry through automation and the
digitization of information.

Some of our ideas will be easily implemented at your business, others may take
some time. But as we all know, a hero’s journey always begins with a single step.

Introduction 5
 2

THE MAGNITUDE OF
MAINTENANCE

“Because the work of every person is built on the work of

another, we all rely on one another. Work connects us all.

- Hilda Solis
”
 Defining Maintenance

Let’s take a moment to look at the current maintenance industry as a whole.

“The Functional Maintenance Organization and Its People.” Rules of Thumb for Maintenance and Reliability
Engineers, by Ricky Smith and R. Keith Mobley, Elsevier/Butterworth-Heinemann, 2008, pp. 28–28.

As seen in the above chart, ‘Maintenance’ is often made up of an array of

departments including operations, facility management and more. For our
purposes, we’ll use the general term ‘maintenance’ throughout this book to
encompass all of the departments that work in harmony to keep facilities running
smoothly.

The Scope of Maintenance

In the US workforce alone, there are over 1.4 million general maintenance and
repair workers keeping life as we know it running.[5] You may be intimately
familiar with how your specific industry impacts the world at large, but consider
how all facets of the maintenance community work together to keep it spinning.
You all not only sustain huge sectors such as wastewater treatment, 3D printing
and manufacturing, but also keep families’ homes safe and the local hospital
functional. Not to mention conserving the road between the two.

The Magnitude of Maintenance 7

Here are some statistics on the breadth of maintenance’s impact on industries
across the nation:

The number of people employed as Installation, maintenance, & repair occupations has been declining at a
rate of -0.67%, from 4,532,763 people in 2016 to 4,502,391 people in 2017. This graphic shows the share of
Installation, maintenance, & repair occupations employed by various industries. Automotive repair &
maintenance employs the largest share of Installation, maintenance, & repair occupations at 14.5%, followed
by Construction with 11.3% and Car Dealers with 5.55%. Data provided by the Census Bureau ACS PUMS 1-Year

In terms of impact on society, consider just one of the industries within

maintenance – manufacturing. U.S. manufacturing alone is so large that if it were
its own country, it would rank as the eighth-largest economy in the world.[6]
Manufacturing accounts for an incredible $2.17 trillion of the total U.S. economy
and is on the rise, up by more than 27 percent from 2009.”[7]

The truth is, maintenance workers like you are responsible for sustaining every
building humans step foot into, every utility used, every product consumed –
really every industry in every country in the world. The impact of your work is felt
everyday, and that’s why we call you heroes.

The reason to invest in getting ahead of technology isn’t a selfish one. Imagine
the ripple effects on our world if we were able to make your role in it even more
productive, even more efficient and a whole lot safer?

The Magnitude of Maintenance 8

 3

UNDERSTANDING THE DIFFERENT

TYPES OF MAINTENANCE

“
Anyone who stops learning is old, whether at twenty or eighty.
Anyone who keeps learning stays young.

”
The greatest thing in life is to keep your mind young.
- Henry Ford
 Getting Started

This section is all about understanding the 4 broad types of maintenance. Yes,
there is a whole suite of different terms in the industry, and they all serve
important functions in the world of maintenance. This does not cover all
maintenance and reliability philosophies and should be used as a great starting
point into maintenance strategies! Ready? Let’s go!

For ease of understanding, we are going to break out maintenance strategies into
4 different groups:

• Breakdown maintenance
• Time based preventative maintenance
• Condition based maintenance
• Predictive maintenance

Understanding Maintenance: Getting Started 10

 3.1

UNDERSTANDING THE DIFFERENT

TYPES OF MAINTENANCE

Breakdown Maintenance
 The Breakdown Maintenance Workflow

Breakdown maintenance (also known as Run-To-Failure maintenance) is a

maintenance strategy that is sometimes more appropriately called “Fit and
Forget” because there is no maintenance plan beyond complete replacement
upon failure. It is an essential technique in certain industries. Take, for example,
the space program where satellites are beyond human reach and simply cannot
be serviced.

In essence, breakdown tells you that no amount of maintenance will refill a

toothpaste tube. When it’s empty, it’s at the end of its useful life. Buy a new one
so it is ready to go when the other fails.

However, breakdown maintenance should not be misconstrued as unintended

failure replacement (UFR) which is failure from neglect or ignorance without a
plan to cope. Breakdown maintenance is a very deliberate strategy where the
item is intended to run until it fails and owners are prepared to take remedial
action instantly upon failure.

There are two types of breakdown maintenance: planned and unplanned.

Planned breakdown maintenance means that the organization is prepared for a

breakdown and even expects it to happen. The equipment runs until it breaks,
which initiates a breakdown trigger. While breakdown triggers can be
unplanned, breakdown maintenance is a way of lowering the cost of
maintenance.

This kind of plan needs to be rigorously documented and controlled. Employees

should be clear on exactly which parts will break down and which parts will be
maintained normally via preventive maintenance. Without these checks, a
breakdown maintenance plan can be exploited or run awry.

Understanding Maintenance: Breakdown Maintenance 12

Unplanned breakdown maintenance, on the other hand, occurs when a piece of
equipment fails or breaks unexpectedly—also called an unplanned downtime
event. While some facilities may not utilize a planned breakdown maintenance
plan, nearly every facility needs resources in place for unplanned breakdown
maintenance. After all, every piece of equipment will break or fault at some point
in its life.

Examples of breakdown maintenance

Breakdown maintenance is unique in its applications because it cannot be used

with certain industries or products, especially ones that involve health and safety.
This means that breakdown maintenance is most frequently used when parts are
inexpensive or nonessential.

Here are some examples in which breakdown maintenance is applicable:

• Equipment can’t be repaired at all (inaccessible, designed to not be repaired)

• Asset consists of inexpensive or easy-to-replace parts
• Non-critical pieces of equipment (like hand tools)
• Equipment that is disposable or to be replaced at the end of their lifespan
• Short-life assets (batteries, high flow pumps)

As you can see from these examples, breakdown maintenance becomes viable
when there’s no inherent safety risk to letting a part or piece of equipment break.
As an example, consider a facility’s light bulbs. If a light bulb is not linked to a
safety feature, it doesn’t make financial sense to replace it before it has burned
out.

However, breakdown maintenance is absolutely not viable when peoples’ lives

can be endangered by a part or product breaking. For example, the aviation
industry cannot rely on parts breaking down to fix them because doing so could
threaten the personal wellbeing and safety of people on planes. This is also true
for tire manufacturers who are responsible for road safety. When it comes to
peoples’ lives, preventive and predictive maintenance are the right choice.

Understanding Maintenance: Breakdown Maintenance 13

 Benefits of run to failure maintenance

There are two possible beneficial outcomes while using breakdown

maintenance: economizing costs and enhancing productivity. Ideally it is a
mixture of both.

Breakdown maintenance can save money by eliminating the impact of regular

maintenance. Inspecting and cleaning all of the sprinkler heads on a farm or golf
course would have a huge time impact, driving up costs. It’s much simpler to note
the occasional failure and replace the whole unit. The same could be said about
drop ceiling tiles; or other damage are simply replaced since it is impractical to
repair them.

To streamline and enhance operations to improve productivity, a facility with

dozens of people assembling electronics will probably have replacement parts in
bulk. Soldering irons, magnifying glasses, multimeters, and so on, are too
inexpensive to maintain, and too labor intensive to service.

Examples

Run to failure maintenance requires good judgement. Knowing when to declare

wholesale failure as opposed to initiating repair is part of the skill set. Here are a
few examples of ideal breakdown maintenance scenarios.

It is also ideal for short life assets that are not robust or particularly durable in
design. This includes incandescent light bulbs, overhead door motors, circuit
pumps, water heaters, air-traffic warning lights on radio towers, or anything that

Understanding Maintenance: Breakdown Maintenance 14

is typically replaced 5 or more times in the lifetime of a building.

This also applies to disposable assets are items which are generally inexpensive
or single use. These could include car shock absorbers, automobile tires, signage,
pneumatic pistons on assembly lines, most printer cartridges, all the way down to
brooms and mops.

Conclusion

At its worst, breakdown maintenance is referred to as crisis maintenance because

the status of equipment is unknown and the company faces unpredictable
downtime when something breaks. Once implemented on appropriate assets,
with intelligent planning for dealing with the inevitable failures, it saves time,
saves money, and contributes to enhanced productivity.

Understanding Maintenance: Breakdown Maintenance 15

 3.2

UNDERSTANDING THE DIFFERENT

TYPES OF MAINTENANCE

Time Based Preventive Maintenance

Fun fact: 80% of manufacturing plants use some form of preventive maintenance.
 The Preventive Maintenance Workflow

Preventive maintenance, also spelled preventative maintenance, is a type of

proactive maintenance that keeps assets in good order and reduces unscheduled
downtime and major repairs.There are many different types of preventive
maintenance that require different technologies and expertise.

Preventive maintenance is carried out with the goal of increasing asset lifetime by
preventing excess depreciation and impairment or untimely breakdown. This
maintenance includes, but is not limited to, adjustments, cleaning, lubrication,
repairs, and parts replacements.

Time-based preventive maintenance

A recurring work order is scheduled for when a specified time interval is reached
in the computerized maintenance management system (CMMS).

Benefits of preventive maintenance

There are more benefits of implementing a preventive maintenance program

than merely reducing the amount of unplanned downtime. Other benefits
include:

Understanding Maintenance: Time Based Preventive Maintenance 17

Think about it in simple terms such as with your car. Oil changes and regular
servicing are part of a preventive maintenance schedule that ensures your car
runs properly and without unexpected failure. If you ignore that maintenance
schedule and miss service intervals, your car will depreciate in value and utility.
The same goes for machinery in manufacturing plants and equipment in facilities.

With a PM schedule in place, maintenance managers can decrease downtime.

This schedule is usually automated with a CMMS that comes with PM scheduling
software. However, managers are always cautious of over-maintaining assets.
There’s a point where preventive maintenance starts costing too much in relation
to the amount of downtime it prevents.

“EMIT Optimisation – Getting More out of Existing Equipment for Less.” Risktec – The Newsletter of Risktec
Solutions, 2017, www.risktec.tuv.com/risktec-knowledge-bank/asset-integrity-management/emit-optimisation-
getting-more-out-of-existing-equipment-for-less/.

There are more benefits of implementing a preventive maintenance program

than merely reducing the amount of unplanned downtime.

Understanding Maintenance: Time Based Preventive Maintenance 18

Other benefits include:

• Extension of asset lifetime

• Increased safety and reduced risk of injury
• Optimized maintenance planning and resource allocation
• Less expensive corrective repairs
• Better margins and profits due to less downtime
• Perhaps the greatest benefit is increased safety, especially for a company that
owns heavy machinery. The price of employee safety is never too high and
organizations such as the Occupational Health and Safety Administration
(OHSA) rigorously enforce government policy.

Examples of preventive maintenance

Some aspects of a solid preventive maintenance program are obvious.

Production line equipment should be suitably maintained to prevent breakdown,
and infrastructure elements such as heating, ventilation, and air conditioning
(HVAC) should be routinely inspected, cleaned, and updated as required.
However, there may be other systems that also need routine maintenance to
prevent failure.

How about your water systems? Do you have appropriate filtration? Are you
running warm water systems that may be a breeding area for serious bacterial
infections such as Legionnaires Disease? How about your electrical systems and
the need to ensure that they not only comply with legislation but do not degrade
over time? Doors, stairways, lighting, and flooring all need periodic inspection
and maintenance, too.

The list of what needs to be included in your preventive maintenance plan can be
bewildering, but there are certain guidelines that give you at least a basis to
conform too. The American National Standards Institute (ANSI) carries a lot of
information on preventive maintenance and is a good place to start if you are
unsure as to the extent of the program that you need.

Understanding Maintenance: Time Based Preventive Maintenance 19

 Important questions to ask yourself

Preventative Maintenance is the most common form of maintenance, but time

based maintenance schedules only capture about 20% of issues. This means 80%
of the time, maintenance teams over-PM or under-PM your assets, so be sure to
ask yourself, “Do I have the right metrics and KPI’s to make sure I selected the
right time based interval”?

Conclusion

Preventive maintenance is often seen as an overhead cost that is difficult to

justify. But it takes just one period of downtime or a single notifiable accident to
demonstrate how important it is to undertake a program of forward-looking
maintenance.

To start implementing a PM program, choose a few critical assets, make a

preventive maintenance checklist, then schedule the PMs in a CMMS.

Understanding Maintenance: Time Based Preventive Maintenance 20

Sullivan, G. P., et al. Operations & Maintenance Best Practices A Guide to Achieving Operational Efficiency.
FEDERAL ENERGY MANAGEMENT PROGRAM, 2010, Operations & Maintenance Best Practices A Guide to
Achieving Operational Efficiency, www.energy.gov/sites/prod/files/2013/10/f3/omguide_complete.pdf.

Understanding Maintenance: Time Based Preventive Maintenance 21

To help you get started, we’ve collated some helpful sample checklists below
from the U.S. Department of Energy’s Operations & Maintenance Best Practices –
A Guide to Achieving Operational Efficiency:

Sullivan, G. P., et al. Operations & Maintenance Best Practices A Guide to Achieving Operational Efficiency.
FEDERAL ENERGY MANAGEMENT PROGRAM, 2010, Operations & Maintenance Best Practices A Guide to
Achieving Operational Efficiency, www.energy.gov/sites/prod/files/2013/10/f3/omguide_complete.pdf.

Understanding Maintenance: Time Based Preventive Maintenance 22

 3.3

UNDERSTANDING THE DIFFERENT

TYPES OF MAINTENANCE

Condition Based Maintenance

Fun fact: 10% (and maybe even less) of industrial equipment ever actually wears out,
meaning a very large portion of mechanical failures are avoidable.
 Condition-based maintenance workflow

Condition-based maintenance (CBM) uses sensor devices to collect real-time

measurements (ie. pressure, temperature, or vibration) on a piece of equipment.
This data allows maintenance personnel to perform maintenance at the exact
moment it is needed.

Condition-based maintenance uses meter measurements to perform maintenance

only when that equipment may fail or needs repairs. You determine the precise
maintenance point via visually inspecting a piece of equipment, performing tests on
equipment specs, or gathering data and diagnostics. CBM allows maintenance
personnel to act on a by-need basis, optimizing the amount of time spent on
maintenance tasks.

This type of maintenance uses both condition monitoring and condition

measurements. Condition monitoring measures specific equipment parameters (like
vibrations in a system), taking note of drastic changes that could be indicative of a
fault. Maintenance personnel take regular condition measurements from these
parameters, which provides the current view of the equipment’s health. As
equipment health dips, maintenance personnel perform work and return the
equipment to its working state.

Condition-based maintenance uses equipment measurements to perform

maintenance only when that equipment may fail or needs repairs. You determine
the precise maintenance point via visually inspecting a piece of equipment,
performing tests on equipment specs, or gathering data and diagnostics. CBM
allows maintenance personnel to act on a by-need basis, optimizing the amount of
time spent on maintenance tasks.

Understanding Maintenance: Condition Based Maintenance 24

This type of maintenance uses both condition monitoring and condition
measurements. Condition monitoring measures specific equipment parameters (like
vibrations in a system), taking note of drastic changes that could be indicative of a
fault. Maintenance personnel take regular condition measurements from these
parameters, which provides the current view of the equipment’s health. As
equipment health dips, maintenance personnel perform work and return the
equipment to its working state.

Benefits

By monitoring equipment parameters in real time, CBM systems reduce downtime

(and can even eliminate downtime as a whole). For example, your system measures
the amount of noise produced by a motor, and a higher noise level indicates that
the motor needs to be replaced. Because the equipment runs on a condition-based
maintenance system, maintenance personnel will know exactly when to replace that
motor because of this noise measurement. The moment the noise reaches an
unacceptable level, the motor will be replaced.

That means you don’t need to wait until the machine faults out or the motor breaks
and causes a massive downtime event. The unplanned downtime goes away, and in
its place is maintenance work that takes place at a defined, measured point in time.

Understanding Maintenance: Condition Based Maintenance 25

 Examples of condition-based maintenance

Condition-based maintenance works similarly to the warning lights in your car. For
example, the oil light doesn’t pop up when your car is running on its last few drops.
Instead, it conditionally measures the oil content of your car and lets you know
when you need to change or replenish the oil. This information allows you to make
an informed decision to maintain your vehicle.

This is true of manufacturing environments as well. If a machine produces a certain

amount of heat under normal conditions but heats up quickly when an energy
problem exists, an infrared camera can detect the change in heat and the system
can dispatch a maintenance technician.

Another example is pressure readings. When a large amount of water flows through
pipes, the water produces considerable pressure; fluctuations in this pressure can
cause problems when water is needed (low pressure) or too much water is flowing
(high pressure). Reliably diagnosing pressure issues can save a lot of headache in
any industry that relies on water cooling systems.

Conclusion

Condition-based maintenance may seem too expensive for too little benefit.
However, in any organization with critical equipment, a CBM system can prove its
worth twice over when it comes to reducing or even eliminating unscheduled
downtime.

Understanding Maintenance: Condition Based Maintenance 26

 3.4

UNDERSTANDING THE DIFFERENT

TYPES OF MAINTENANCE

Predictive Maintenance

Fun fact: PdM can lead to a 25 to 30% decrease in maintenance costs!

 The Predictive Maintenance Workflow

Predictive maintenance (PdM) is the most advanced type of maintenance currently

available. With time-based maintenance, organizations run the risk of performing
too much maintenance or not enough. And with reactive maintenance,
maintenance is performed when needed, but at the cost of unscheduled
downtime. Predictive maintenance solves these issues. Maintenance is only
scheduled when specific conditions are met and before the asset breaks down.

PdM relies on IoT devices that monitor conditions of assets. Different assets are
monitored in different ways (vibrational analysis, acoustical analysis, infrared
analysis). This data is used to predict when the asset will require maintenance to
prevent equipment failure. A continuous or online approach is used to monitor
conditions of assets. Remote monitoring is also possible by connecting an IoT
sensor device to maintenance software. When specific conditions are met, a work
order for an inspection is triggered.

Understanding Maintenance: Predictive Maintenance 28

 Types of predictive maintenance

A) Vibrational analysis

Machine Speed: High | Machine Type: Mechanical | Cost: Medium

This is the go-to type of analysis for predictive maintenance inside manufacturing
plants with high-rotating machinery. Because it’s been around longer than other
types of condition monitoring, it’s relatively cost-effective. In addition to detecting
looseness like in the example above, vibrational analysis can also discover
imbalance, misalignment, and bearing wear.

B) Acoustical analysis (sonic)

Machine Speed: Low, High | Machine Type: Mechanical | Cost: Low

This type of analysis requires less money to implement and is used for low- and
high-rotating machinery. It’s particularly popular among lubrication technicians.

According to an article by Machinery Lubrication, “Acoustic analysis is similar to

vibration analysis; however, its focus is not to detect causes for rotating equipment
failure by measuring and monitoring vibrations at discrete frequencies and
recording data for trending purposes.

Instead, acoustic bearing analysis is intended for the lubrication technician and
focuses on proactive lubrication measures.”

C) Acoustical analysis (ultrasonic)

Machine Speed: Low, High | Machine Type: Mechanical, Electrical | Cost: High

While sonic acoustical analysis borders on the line of proactive and predictive
maintenance, ultrasonic acoustical analysis is solely used for predictive
maintenance efforts. And because it can identify sounds related to machine friction
and stress in the ultrasonic range, it’s used for electrical equipment that emit
subtler sounds as well as mechanical equipment. It’s argued that this type of
analysis predicts imminent breakdowns better than vibration or oil analysis.

Understanding Maintenance: Predictive Maintenance 29

D) Infrared analysis

Machine Speed: Low, High | Machine Type: Mechanical, Electrical | Cost: Low

This type of analysis is not dependent on an asset’s rotational speed or loudness.

Therefore it’s suitable for many different types of assets. When temperature is a
good indicator of potential issues, infrared analysis is the most cost-effective tool
for predictive maintenance. It’s often used to identify problems related to cooling,
air flow, and even motor stress.

Example of predictive maintenance

A centrifugal pump motor in a coal preparation plant is a vital asset for day-to-day
operations. To prevent unscheduled downtime, the maintenance team decides to
use predictive maintenance technology. Because it’s a large piece of mechanical
equipment that performs heavy rotations, the obvious choice is to monitor
vibrations with vibration meters.

The team attaches a vibration meter close to the pump’s inner bearing and
establishes a normal baseline measurement, visualized through a waveform graph
(below, left). A few months later, the vibration meter identifies a spike in
acceleration (below, right). The maintenance team reviews this new data remotely
and schedules an inspection. The technician who performs the inspection finds a
loose ball-bearing and repairs it.

Moving forward, the team connects the vibration meter to its CMMS. Now, when
the same spike is identified, a fault with the ball-bearing is predicted and a work
order is automatically triggered to perform the repair.

Conclusion

Predictive maintenance is not for every organization, especially those that have yet
to implement planned maintenance. But for larger organizations that have
outgrown traditional PMs and have additional budget, predictive maintenance can
provide an ROI that turns the maintenance department into a source of cost-
savings and higher profits.

Understanding Maintenance: Predictive Maintenance 30

Some helpful sample checklists below:

Sullivan, G. P., et al. Operations & Maintenance Best Practices A Guide to Achieving Operational Efficiency.
FEDERAL ENERGY MANAGEMENT PROGRAM, 2010, Operations & Maintenance Best Practices A Guide to
Achieving Operational Efficiency, www.energy.gov/sites/prod/files/2013/10/f3/omguide_complete.pdf.

Understanding Maintenance: Predictive Maintenance 31

 4.1

HOW TO EXECUTE
A MAINTENANCE PLAN

“ Yesterday’s skills will not fuel tomorrow’s economy.

- Elaine Chao ”
 THE ULTIMATE GUIDE FOR CHOOSING A MAINTENANCE STRATEGY

If you don’t have a maintenance plan at your business, it’s time to make one.

This section is for those just starting on their maintenance hero journey. If you do
not have an intentional plan in place for maintenance on your equipment, start
here.

INSTRUCTIONS

We’ve provided the simplest way to get started picking the right maintenance for
your business below. First, break out your existing assets into this 2×2 matrix that
plots each equipment by the cost of failure by costs to track. While this isn’t the
most thorough way to assess your maintenance needs, it is helpful in guiding you
on how to start.

Take all of your assets and rate each on the 1-10 scale below. As a general rule,
assets are any pieces of equipment that are over $2000 in value OR are critical to
your business. *Note, use your best judgement and this is meant to be a relative
exercise!

1= high cost to track condition → 10= easy/low cost to track condition

1= high cost of failure → 10= low cost of failure

How To Execute A Maintenance Plan 33

Next, plot each piece of equipment on this diagram. Note that you will have assets
under different quadrants on the chart. This is right as each piece of equipment will
have its own ideal form of maintenance.

Now that you have an idea of which kinds of maintenance you should invest in
moving forward, read on to your specific section for more on this type of
maintenance and how to get started.

Step 1 – Collecting Data – Add your assets

• Document all of your equipment

• If you run maintenance on components of equipment, be sure to include that as

well.

• Put them into a spreadsheet that looks like the sample below. Your key columns
should be: asset name, asset category, asset cost, and lifetime

Asset Name Asset Category Asset Cost Lifetime

Main Lobby HVAC HVAC $10,000 10 years

Main Lobby HVAC – Heat

HVAC $2000 5 years
exchanger

Main Lobby HVAC –

HVAC $1000 3 years
Condensing Unit

STEP 2 - Collecting Data - Score on Cost of Failure

Score all of your equipment in a 1-10 based on the cost of failure of this asset. The
cost of failure should include all things including:

How To Execute A Maintenance Plan 34

• Downtime costs
• Regulatory cost
• What are all of the risks from a hazard, safety, etc perspective
• What is the probability of failure?
• Replacement costs

STEP 3 - Collecting Data - Score on ability to track condition

Score all of your equipment from 1-10 based on the ability to measure and track the
condition of your equipment. When thinking about the cost to measure
performance and track condition, be sure to include:

• Technician time to measure performance

• Cost of sensors
• Cost of time to implement
• Do we currently have the resources

ETC - Cost of Cost to measure

Asset Asset
Asset Name Lifetime Additional Failure of performance and
Category Cost
Custom Data Asset track condition
Main Lobby
HVAC $10,000 10 years ****
HVAC
Main Lobby
HVAC – Heat HVAC $2000 5 years 6 4
exchanger
Main Lobby
HVAC –
HVAC $2000 3 years 3 5
Condensing
Unit

How To Execute A Maintenance Plan 35

 Step 4 – Collecting Data – Plot data points

Plot all of your assets on this grid to help you determine the correct maintenance
strategy

Your equipment may have many different maintenance strategies which is why it is
important to showcase your sub-assets

This is an exercise to help guide you — this is not the only way to do this.

How To Execute A Maintenance Plan 36

 Step 5 – Collecting Data

• Take all of your equipment and start assigning maintenance strategies.

• If you have regulatory compliance, you’ll want to use those guidelines, not this
guide.

• Go through all of your assets in run to failure. Are you sure you want to run
these into failure? Did we categorize this correctly?

• If you have a component on an asset that is a single point of failure for your
equipment, you’ll want to make sure that inherit the cost of the failure to be the
main asset. For example, the HVAC could be a 6 cost of failure, and if the heat
exchanger goes down then it takes the entire HVAC down, the heat exchanger
should also be a 6 for cost of failure.

ETC - Cost to measure

Cost of
Asset Asset Additional performance Maintenance
Asset Name Lifetime Failure of
Category Cost Custom and track Strategy
Asset
Data condition
Main Lobby
HVAC $10,000 10 years **** Multiple
HVAC
Main Lobby Time based
HVAC – Heat HVAC $2000 5 years 6 4
exchanger Preventive
Main Lobby
HVAC – Condition
HVAC $2000 5 years 4 5
Condensing Based
Unit

How To Execute A Maintenance Plan 37

 Step 6 - Settings up reports and establishing KPIs for the team

• Run a few reports

• You can now track how many assets have multiple maintenance strategies

• Create a dashboard that displays

▪ What % of your assets are in run to failure, preventive, condition based, etc?
▪ And what value of your assets are in maintenance strategy bucket?

• As a company is this where you want to be?

• For all of your assets in preventive maintenance — track schedule compliance

etc

• Here are some KPIs to track based on your maintenance strategy

Maintenance Strategy Primary Metric Secondary Metric Tertiary Metric

Run to failure Parts cost Time to resolution. If it
maintenance breaks, how long until
we get it back up and
running MEAN TIME
TO REPAIR
Time Based Schedule compliance. Mean time between
Preventive TIP: Shoot for 90%+. failure. Use this metric
Maintenance Jobs done on time to see if we are OVER
– PM’ing or UNDER
PM’ing
Condition Based # hours of downtime Mean time between Schedule compliance.
Maintenance failure. Use this metric TIP: Shoot for 90%+.
to see if we are OVER Jobs done on time
– PM’ing or UNDER
PM’ing
Predictive OEE – Overall Total planned work in Predictive
Maintenance equipment the planner’s backlog maintenance
effectiveness and that was generated schedule compliance
asset utilization. The by PdM work. Your
pace-setter targets target should be four
are typically above 92 to six weeks of
percent in most backlog, 50 percent
industry verticals, but of which should be
take into account predictive
your operating maintenance.
context when (https://www.reliable
defining your targets. plant.com/Read/2430
/measuring-cbm-
program)

How To Execute A Maintenance Plan 38

 Step 7 – Start Taking Action — Time Based Preventive Maintenance

• Go through all of your assets in the time based preventive maintenance bucket

• Start creating PM schedules for each. You can use this as a guide for choosing
the correct interval

• https://www.idcon.com/resource-library/articles/preventive-
maintenance/479-how-decide-frequencies.html

• Here is a common checklist for preventive maintenance:

https://www.onupkeep.com/blog/preventive-maintenance-checklist/

Step 8 - Start Taking Action - Condition Based Maintenance

• Purchase the equipment to log and track

• Set up the correct intervals for your team to run condition based maintenance

STEP 9 - Start Taking Action - Predictive Maintenance

• Start small. Be sure you have strong leadership and a hard-working team in
place, and don’t try and take it all on at once.

• Identify PdM ready assets. Choose your pilot assets wisely, not at random.

• Identify resources required. Prepare the labor, materials, facilities, technology

(sensors), and training to start your PdM program.

• Implement asset monitoring and begin data collection. Install new

technologies and collect baseline data.

• Create algorithms to predict failures. Design algorithms to process and analyze

data from your new PdM technologies.

• Apply to pilot asset. Use PdM technologies and algorithms to monitor and
provide insights on your pilot asset.

• Establish continuous implementation and improvement process. Synthesize

learnings to prove your PdM program’s value and continue to improve before
begin taking steps to scale.

How To Execute A Maintenance Plan 39

 Step 10 - Improvement Process: Get Better Data

• Now this entire process starts from the very beginning and it starts with better,
higher quality data

• Understand what actions worked

• Track your KPIs and understand the actual cost of failure of your equipment to
decide whether you want to change your maintenance strategy

• Identify bottlenecks in your process

• Move condition based maintenance to predictive

How To Execute A Maintenance Plan 40

 4.2

MAINTENANCE VS RELIABILITY
 STEP 1 - Understand failure modes

Failure Mode and Effects Analysis (FMEA) is a helpful tool to: (a) recognize and
evaluate the potential failure(s) of an item or process and the effects of that failure,
and (b) identify actions that could eliminate or reduce the likelihood of the
potential failure occurring (probability of occurrence).

The performance of an asset relates to its current ability to meet current and future
demands. Assets can fail in four major ways, known as primary failure modes,
which can be used to determine the most appropriate investment strategies
relevant to the asset.

The four Primary Failure Modes are: Physical Mortality, Level of Service, Capacity,
and Financial Efficiency.

We have included a step-by-step process below to begin assigning failure modes

to your assets and make a prioritized plan as an organization. With each example,
a template has been provided at the end of that step for you to follow along.

Maintenance vs. Reliability 42

 STEP 2 - Organize your assets and brainstorm failure modes in the
template provided

Think of anything that can go wrong and use the chart below of examples to help
you.

Failure Description and Assessment Technique Management

Mode Drivers Strategy

Physical Asset deterioration Condition Renewal, O&M

Mortality reduces Level 1 – Staff Knowledge – Desktop Optimization
performance below ‘Delphi’
an acceptable level. Level 2 – Intermediate level Physical
Age, Usage, Inspection (See Appendix A)
Operational Level 3 – Advanced Physical Testing and
Stresses, Acts of inspection
Nature
Capacity Demand exceeds Capacity Redesign
design capacity Level 1 – Staff Knowledge – Desktop
‘Delphi’
Level 2 – Desktop Capacity Modeling
Growth and System
Level 3 – Capacity Modeling with Field
Expansion
Data
Level of Functional and Regulations, Quality, Safety, Service, Noise, Redesign, O&M
Service Reliability Odor Optimization
requirements Function
exceed design Level 1 – Staff Knowledge – Desktop
capability ‘Delphi’
Level 2 – Process Assessment
Level 3 – Strategic Planning
Reliability
Level 1 – Staff Knowledge – Desktop
‘Delphi’
Level 2 – Desktop Analysis
Level 3 – Work Order History (MTBF)
Financial Cost of Operation Efficiency Replace
Efficiency exceeds feasible Level 1 – Staff Knowledge – Desktop
alternatives ‘Delphi’
Level 2 – Desktop LCCA (Estimated Data)
Level 3 – LCCA with Field Data
New Technology,
Wear, Spare Parts

TEM PLATE

Asset Name Possible Failure Modes

Maintenance vs. Reliability 43

STEP 3 – Rate the likelihood of occurrence of each failure mode based
on the below rubric.

Add your rating to your template.

Likelihood of Criteria: Possible Failure Rates/Probability of Failure Rating

Occurrence
Extremely High Failure rate of less than 5 FPMH/Probability of Failure During 10
Mission <0.2
Very High Failure rate of less than 2 FPMH/Probability of Failure During 9

High Failure rate of less than 1 FPMH/Probability of Failure During 8

Mission <0.05
Moderately High Failure rate of less than 200 FIT/Probability of Failure During 7
Mission <0.01
Moderate Failure rate of less than 100 FIT/Probability of Failure During 6
Mission <0.005
Moderately Low Failure rate of less than 20 FIT/Probability of Failure During 5
Mission <0.001
Low Failure rate of less than 10 FIT/Probability of Failure During 4
Mission <0.0005
Very Low Failure rate of less than 2 FIT/Probability of Failure During 3
Mission <0.0001
Extremely Low Failure rate of less than 1 FIT/Probability of Failure During 2
Mission <0.00005
Remote Failure rate of less than 0.2 FIT/Probability of Failure During 1
Mission <0.00001

TEM PLATE

Asset Name Possible Failure Modes Likelihood

Maintenance vs. Reliability 44

 STEP 4 – Rate the severity of each failure mode for your assets using
the below rubric as a guide.

Add your severity rating to your template.

Severity Criteria Rating

Extremely High Catastrophic: Serious injury or loss of life. 10
Very High 9
High 8
Moderately High 7
Moderate 6
Moderately Low 5
Low 4
Very Low 3
Extremely Low 2
Remote Mirror: No loss of downtime 1

TEM PLATE

Asset Name Possible Failure Modes Likelihood

Maintenance vs. Reliability 45

 STEP 5 – Assign a priority number to each asset

To do this, multiple your severity rating x your likelihood of occurrence rating.

Here, you can see how our example results in clear priority numbers. Add your
priority numbers in your template.

Risk Priority
Asset Likelihood of
Asset Name Primary Failure Mode Severity Number (Severity *
Category occurrence
Occurence)
Outside air filtration
HVAC - Air
HVAC blockage. (normal & 3 6 18
Filtration
abnormal events)
HVAC - Air
HVAC 6 7 70
Filtration

TEM PLATE
Risk Priority
Asset Likelihood of
Asset Name Primary Failure Mode Severity Number (Severity *
Category occurrence
Occurence)

Maintenance vs. Reliability 46

 STEP 6 – Understand mitigation by risk priority

Reorganize your template so that you are now viewing your assets from most
important to least. Now, brainstorm a plan of actions or mitigations you can take to
avoid failure in the first place.

Risk Priority
Likelihood Mitigation
Asset Asset Primary Number
Severity of / Action
Name Category Failure Mode (Severity *
occurrence Plan
Occurence)
Outside air Duplicate
filtration outside air
HVAC - Air blockage. 6 due to bio filtration
HVAC 6 18
Filtration (normal & contamination Predictive
abnormal fouling
events) rate
9 due to loss
of control of Standby
HVAC - Air critical fans
HVAC Fan failure 7 54
Filtration parameters. Vibration
Loss of monitor
pressure.

http://research.me.udel.edu/~jglancey/FailureAnalysis.pdf

TEM PLATE
Risk Priority
Asset Likelihood of
Asset Name Primary Failure Mode Severity Number (Severity *
Category occurrence
Occurence)

STEP 7 - Revisit your plan every Quarter.

Maintenance vs. Reliability 47

 5

TECHNOLOGY x MAINTENANCE

This section is for those maintenance heroes who already have maintenance
programs up and running, and a CMMS system in place to constantly track metrics.

Interested in how future innovations offer a unique opportunity for you to better
your business? Read on!
 Industry 4.0

Technology is being introduced into our industries at an ever accelerating pace.

As technologies like AI, IoT and robotics grow increasingly common in industrial
spaces, a new term has been coined for this wave of automation and digitization –
“Industry 4.0,” as in the fourth industrial revolution.

It makes sense why companies are investing in advanced automation solutions.

Technology has the potential to hasten production, pin-point issues never
understood before and bring businesses to new financial heights. Just as certain
jobs are outsourced to other global markets to take advantage of lower
production costs, companies will naturally start to harness cheaper, more capable,
and more adaptable technological solutions to make their output more
economically lean and efficient. In 2017, there were just over two million industrial
robots operating commercially. [1] It’s projected that 4.4 million units will be
installed by 2023.[2]

In Japan, robotics manufacturer FANUC has operated a “lights-out” factory since

2001. Lights-out manufacturing refers to autonomous factories that require no
human presence to operate. These robot-run factories are building other robots at
a rate of about 50 per day, and can do so unsupervised for as long as 30 days at a
time, all completely in the dark. “Not only is it lights-out,” said FANUC VP Gary
Zywiol, “we turn off the air conditioning and heat too.”

FANUC once required 650 workers to keep the factory running. This technology
has cut its human workforce down to just 60 workers, less than a tenth of its
original manpower.

The McKinsey Global Institute has found that, “robotics and AI technologies such as
machine learning (which gives computers the ability to learn without explicit
programming) have advanced to the point where it would be possible to
automate at least 30 percent of activities in about 60 percent of occupations in
both the United States and Germany.” [3] Automotive companies such as Tesla are
already using AI technologies in their autonomous vehicles. By 2030, highly
autonomous vehicles could account for 10 to 15 percent of new car sales. [4]

Governments, too, have taken note of Industry 4.0’s benefits. Take the value to
public safety in construction. Through IoT technology, machines can seamlessly

Technology x Maintenance 49
talk to each other and react to problems as they arise. Not only can agencies
precisely monitor and check existing infrastructure for dangerous behaviors during
seismic events, or how bridges bend under the weight of passing traffic, but also
use this data to improve future construction practices.

Even if these examples leave you feeling like we’re living in a future pulled directly
from the pages of a sci-fi novel, the fourth industrial revolution’s capabilities has
not yet been tapped to its full potential. “Despite employing 8.5% of Americans,
manufacturing remains an area of relatively low digitization — meaning there’s
plenty of headroom for automation and software-led improvements. [5] There are
over 612,000 bridges in the United States alone; nearly 56,000 of these are in need
of repair. [6]

Automation in our world today

We’ve already seen automation’s incredibly beneficial effects on the individuals in

maintenance at two polar opposite ends of the spectrum: from the simple and
routine, to the extremely high risk.

HIGH RISK

At offshore drilling sites, plants process and test gas and oil with flare stacks
looming overhead. In this environment, any breakdown can cause catastrophic
failure, and peoples’ jobs are to maintain the facilities are to a super high standard
through routine inspections. These inspections INCLUDE climbing to the top of the
flare stack. Instead of the flare stack inspectors being dangerously suspended 200
ft off the ground, we now have drones that complete this routine inspection.

The important point of this example is that these sites still need the flare stack
inspector, but this individual is now on the other side of a screen completing the
inspection, not suspended in the air next to the highly dangerous flare stack.

Technology x Maintenance 50
 SIMPLE:

Let’s now look at how automation can help free up human capacity by taking on
routine, time-consuming activities. In membrane manufacturing plants, people
manually inspected membranes to perform quality control for up to 8/9 hours a
day. In order to streamline processes, facilities can now use a laser camera that
stands on top of the line and scans for defects. By making this switch, the facility is
able to take that headcount somewhere else and human capacity is freed-up to
create new products and new tasks.

It’s crucial here to realize who exactly supports the technology that now
automatically scans the membranes. The individuals who used to perform this task
manually are those with the exact skills to install, implement and maintain the
scanning equipment.

There are jobs that we cannot automate,

and there are those that we simply shouldn’t.

Most tasks within the maintenance wheelhouse have yet to be automated. This
most likely has to do with the fact that these roles are not easily programmable.
Lubing bearings and replacing filters, for example, are all important routine
functions that may at first appear easily programmed, but they both serve more
complex purposes than the initial task at hand. When completing these routine
tasks, maintenance workers are often taking the opportunity to inspect the rest of
the assets. They’re using their 5 senses and running a sophisticated decision-tree in
their minds to understand if further action is required – even if they don’t know
exactly how they’re doing it. This process is an algorithm that is hard for a
maintenance tech to articulate – and thus – hard to program into a computer.

Some job functions are nearly impossible to program. In maintenance, how often
has a problem been investigated because your 5 senses told you something was
‘off?’ The machine made a ‘weird’ sound or the air felt ‘different?’ At the end of the
day, all of Industry 4.0’s advancements are programmed for, and by, humans.
Sophisticated decision trees that have developed in your mind after countless trial
and errors are hard to code into a computer. There will always be a need for a
humans to assess for edge cases – the things we haven’t yet programmed for,
because we don’t yet know why the issue is occurring.

As discussed previously, a lot of jobs and processes will be automated, but we

don’t want to go so far as to say that a robot can do everything a human can do.

Technology x Maintenance 51
Technology doesn’t substitute for jobs, instead, it takes on tasks, and by doing so,
allows humans to evolve their roles.

In the future

For maintenance’s Industry 4.0 revolution to be most successful, it will rely on two
knowledge centers – data scientists who understand how to harness the power of
digitized information, and those who know how to operate the machines
themselves.

We argue that you, the operator, are the best person to combine both. Today’s
mechanic might become tomorrow’s ‘reliability engineer.’

A common fear is that a small number of data scientists and machines will replace
the bulk of the maintenance workforce. However, data scientists won’t necessarily
understand the infinite nuances that go into a mechanic’s work without
accumulating their own firsthand experience on the facility floor. Therefore, while
there will be a learning curve for mechanics who need to interpret data, there will
also be a learning curve for data scientists who need to understand the practical
applications of that data. How often have the instructions in an asset’s manual been
inaccurate? An extensive anthology of firsthand experiences exists in your brain
alone, and data scientists who have never stepped foot in a manufacturing facility
will rely on technicians like you to utilize industry-specific technology. Instead of
looking at these two fields as separate factions, it’s more realistic to view them as
having a more organic and symbiotic relationship.

The idea that the machines themselves are going to take over the world is
perpetuated by pop culture and science fiction, but it’s not a very accurate
reflection of how software is being developed. Machine learning and predictive
analytics enable you to do your job better, smarter, faster, and safer. Industrial AI is
being designed to work for, and alongside, technicians with experiential
knowledge of how equipment works on-site. It’s best to think of this technology as
a handy sidekick – one that provides insights you can interpret and apply to your
individual workflow.

One of the most exciting things about this process will be the shift from jobs that
are reactive to those that are proactive. Mechanical breakdowns happen because
of breakdowns in information.

Technology x Maintenance 52
The more data that is generated and the quicker this data can be interpreted, the
better individuals will get at predicting and preventing breakdowns from
happening in the first place.

New technologies are going to allow a completely new type of facility technician
to thrive, one who is more focused on utilizing technology and data to drive
important decisions. Instead of repairing equipment on-site, mechanics will
become experts at analyzing data and trends to improve the output, efficiency,
and durability of their equipment.

If 80% of asset failures are currently categorized as ‘random,’ and only 20% are due
to age-related issues, imagine the potential for our industry if large data sets are
made available to someone with your expertise? Imagine the patterns – the cause
and effects – only you will be able to unlock?

The maintenance worker’s role

We are starting to see maintenance turn from fire fighting and maintaining status
quo — to now a focus on overall equipment efficiency (OEE)

Currently, there are three types of maintenance workers:

• The Fire Fighter – something breaks and you fix it. This role is purely reactive.

• The Maintainer – you keep a piece of equipment or process running smoothly

in order to preserve the status quo. However, the key to being at the forefront
of the automation revolution is becoming the third type of maintenance
worker: The Process Improver.

• The Process Improver – you don’t just fix or maintain, you proactively improve
entire systems and operations. How can we be improving processes always?

With automation taking on tasks normally covered by the Maintainer and Fire
Fighters, you have an opportunity to harness the power of technology to become
the Process Improver for your business.

Technology x Maintenance 53
 The far-reaching benefits of technology

Technology in the maintenance industry doesn’t just benefit the businesses’

bottom lines, nor your day-to-day role at said business. We’ve always looked at
maintenance workers as the unsung heroes of society. Let’s take a moment to think
through how outfitting the globe with Industry 4.0 capabilities will allow us to live
in a world where:

• Fewer planes will crash, because every part on every aircraft will be
electronically monitored so they can be quickly replaced at the slightest sign of
failure. [7]

• Cost of goods from food, to housing, to products will go down bringing an

overall higher standard of living. Additionally, General Electric concluded the
Internet of Things over the next 20 years could add as much as $15 trillion to
global GDP, which it noted is roughly “the size of today’s U.S. economy.” [8]

• Plus, these goods will be higher quality with fewer defects. If you think about
minor blemishes, that’s a small thing. But when you think about food quality, for
example, and major outbreaks that have happened as of late- E. coli and
Listeria- to name just a few. A lot of it is due to aging processes, equipment and
poor quality control.

• The planet benefits from less waste. With reduced malfunctions, improved
demand forecasts and optimized energy usage the entire planet can breathe
easier knowing that less pollution and waste are being created.

• More funds for education. Nationwide, schools spend $8 billion per year on
energy. Energy-efficient maintenance programs can save school districts up to
20% on energy bills – funds which then could be allocated towards enhancing
students’ educational experiences with state of the art facilities.

See? In the coming decades, maintenance teams will be the heroes that make our
world safer and more sustainable! Plus you’ll get paid more for it too.

The question becomes— are you prepared to become the hero the world needs?

Technology x Maintenance 54
Footnotes:

1. Executive summary, world robotics, International Robotics Foundation, October

2018, ifr.org.

2. McKinsey, 2019 https://www.mckinsey.com/industries/advanced-

electronics/our-insights/industrial-robotics-opportunities-for-manufacturers-of-
end-effectors

3. https://www.mckinsey.com/business-functions/digital-mckinsey/our-
insights/building-smarter-cars

4. Paul Gao, Hans-Wenner Kaas, Detlev Mohr, and Dominik Wee, “Disruptive
trends that will transform the auto industry,” McKinsey.com, January 2016.

5. https://www.cbinsights.com/research/future-factory-manufacturing-tech-
trends/

6. American Road and Transportation Builders Association

7. https://www.dailynews.com/2014/01/08/internet-of-things-promises-
profound-transformation-could-rival-industrial-revolution/

8. https://www.dailynews.com/2014/01/08/internet-of-things-promises-
profound-transformation-could-rival-industrial-revolution/

Technology x Maintenance 55