MAINTENANCE RULES BASED ON CRITICALITY CLASS

# Description Class A Assets Class B Assets Class C Assets

A Prominently display class symbol on the equipment B Same as Class A requirement C Optional

1 Visual display Affix labels for all components on assets Desirable Desirable
Affix alarm values and trip values on the equipment Mandatory Desirable
All field instruments/gauges must have markings for normal/high/low values Mandatory Desirable

2 Equipment master with complete specifications in ERP Mandatory Mandatory Mandatory

Operations-and-maintenance manual,
3 Hard copy must be available at shop floor for ready reference during repairs Soft copy sufficient Soft copy
cross-sectional drawings, etc.
Mandatory during turnaround; detailed report required. For static
4 Inspection, overhauling, cleaning Desirable during turnaround or during breakdown/failure Optional
equipment, follow risk-based inspection document
5 Failure analysis for breakdowns and malfunctions Mandatory; must be completed within a week of failure Desirable but not mandatory. However, maintenance history must be more detailed Optional
To be recorded in great detail immediately after attending to the failure.
6 Failure history Must be maintained within a week’s time with as much detail as possible Desirable
Must include photographs of failed component, wear and tear, etc.
Handle after clearing backlog of Class A and
7 Priority of maintenance work orders Must get top priority (P1) and immediate attention Attend to within two days. Second priority (P2)
Class B priority work orders. Bottom priority (P3)
8 Standard maintenance procedures (SMPs) Must be prepared and made available at shop floor Desirable but not mandatory Optional
9 Spare part bill of material (BOM) Must be kept current and regularly updated in ERP Mandatory Optional
Must have a defined reorder point and safety stock for automatic ordering.
10 Spare part replenishments Desirable. Spares procurement from alternative sources may be allowed Optional
Must be procured only from original vendor
Must maintain a defined insurance spares and capital spares list to ensure
11 Insurance and capital spares, warehouse assemblies availability at all times. Warehouse assemblies must be stocked and available Optional based on lead time Not required
in working condition at all times.
12 Management of change Vendor consultation mandatory for modification approval Vendor consultation desirable but not mandatory Vendor consultation not required
Annual capital and revenue budget must include all Class A equipment Budgeting requirements can be lumped together on the basis of type of asset, e.g.,
13 Budgeting Optional
requirements belt conveyor, pump spare parts, etc.
Must use well-defined key performance indicators (KPIs) such as
14 Equipment performance monitoring mean-time-between-failures and mean-time-to-repair. Must maintain Desirable Optional
records of maintenance cost, lifecycle costs, etc.
15 Troubleshooting guide. Failure-modes-and-effects analysis Must be prepared and available at shop floor Desirable but not mandatory Optional
Select company maintenance staff must receive certified training at vendor Can be outsourced to good maintenance
16 Training needs Maintenance to be done by company’s own trained technicians
site, with only these people authorized to work on that equipment contractors
Always must be maintained within acceptable limits. If vibration exceeds
Vibrations may be allowed to exceed acceptable limits occasionally. Close Vibration measurement not required or less
17 Vibration levels acceptable limits, equipment must be stopped and corrective repairs made
monitoring of vibration trends must take place frequent
even at the cost of some production loss
Not required but regular vibration monitoring with portable vibration analyzer
18 Continuous monitoring device Must be mounted on equipment if not already provided by vendor Not required
required
Preventive maintenance (PM) checklist filling and Checklist must be filled out after PM and the effectiveness of PM tracked
19 Desirable but not mandatory Optional
effectiveness monitoring as a KPI
Must ensure all instrumentation appearing on the piping and
20 Instrumentation Mandatory Optional
instrumentation diagram is on the machine and is properly labelled
All safety devices must be in working condition (not bypassed) and alarm
21 Safety trips and interlocks With proper approvals, settings may be altered temporarily May not be available
and trip settings must comply with vendor recommendations
22 Equipment repairs and rebuilding Spare parts repair or rebuilding must be done only at vendor facility Desirable but not mandatory Can be done in local machine shop

Table 3. Rankings enable differentiating maintenance rules based on an asset’s criticality.