Level 1 PdM programs have spotty coverage and informal standards, while Level 2 programs are experimenting with basic certifications, alarms, and 2 or fewer PdM technologies. Level 3 programs have expanded coverage of equipment, use 3 or more PdM technologies, and have some basic standards and controls in place. Level 4 programs have good practices like higher certifications, integrated technologies, and formal workflows that are typically followed, while Level 5 programs represent best practices with comprehensive coverage, integration, and accountability across all elements.

1. Ways to Measure Your
PdM Program
PdM Maturity Matrix
LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5
ELEMENTS
NOT ENGAGED EXPERIMENTING ENLIGHTENED GOOD PRACTICE BEST PRACTICE
Quartile Coverage Spot checks 4th Quartile 3rd Quartile 2nd Quartile 1st Quartile
Expectations Troubleshoot Optimize Run-to-Failure Do more PdM Enable Proactive Early elimination of defects and
Strategy Workflow Model root causes
Employee Certifications and
Nothing formal Level I certification by Level II certification with Level III certifications to Certifications plus task
Qualifications technology supplier written practices International Standard qualification
Based on individual motivation Some basic database Standards created with Advanced standards
Standards and Controls Nothing formal and skills, multiple people standards created with controls to monitor, formal created and MOC process
inputting data controlled input workflows exist used for changes
PDM MATURITY ELEMENTS
Alarms present, but are Alarms present, both standard Alarms present, both
Alarming Methods Nothing formal No alarms to overall alarms generic or overall alarms and statistical standard and statistical with
review process
Missed Opportunity / Limited and RCA only when prompted, RCA only required on high RCA activity based RCA on failures of all
Investment informal RCA informal in nature profile failures on good triggers monitored equipment
(e.g. Criticality)
Minimum of 5 technologies, Minimum of 5 technologies,
# of PdM Technologies 1 technology 2 or less technologies Minimum of 3 technologies fully utilized (e.g. electrical fully utilized with integrated
and mechanical infrared) NDT program
PdM
Technology Integration None None Minimal integration Fully integrated (database) Fully integrated (database)
Vibration pens, spot Simple, free oil analysis, Single channel vibration,
Types of PdM Tools radiometers, single possible single airborne ultrasonics, infrared Motor testing, oil analysis, ODS / modal capabilities, online
channel analyzer channel vibration camera, paid medium voltage monitoring monitoring of critical equipment
oil analysis
Limited, more interested Some buy-in, looking Good integration, Fully integrated,
Operations Involvement None in focusing on at PdM metrics but reviewing Asset Health, operations accountable
missed opportunities not utilizing understand importance for reliability efforts
Schedule Compliance Less than 50% Less than 60% Average 60-70% Average 70-80% Average 80-90%
Work Order Creation No PdM work orders Reports created, Most PdM findings All PdM findings generate All PdM findings generate
limited work orders generate work orders work orders work orders
Supporting Workflow Elements
Technology Specific
Northing formal Nothing formal Exist and are Exist and are Exist, refined and
Workflows typically followed always followed always followed
Possibly tracking Tracking availability and OEE, product quality, metrics Track lagging and leading
Metrics / Justification Nothing formal production outputs quality (lagging indicators) are reliable indicators and take
and accurate corrective actions
PdM technicians Dedicated resources Dedicated resources, never Dedicated resources,
Resource Allocation None frequently pulled off task to to PdM effort, rarely pulled off task, beginning multi-discipline trained to
perform maintenance pulled off task to multi-discipline training increase effectiveness
perform maintenance
Requalification / Completed on only high Completed to established Completed to established criteria
Commissioning None Spot check based on request criticality machines criteria (e.g. top 75% of (e.g. all equipment
equipment in PdM program) in PdM program)
No formal Criticality Informal Criticality Assessment Formal Criticality Good granularity, could Good granularity, could be
Supporting Reliability ENGINEERING ELEMENTS
Criticality Granularity Analysis performed performed Assessment performed be used to identify asset used to identify asset coverage
(little or no granularity) (good granularity) coverage and work priority and work priority
SUPPORTING RELIABILITYEngineering Elements
Overall Asset Health Asset Health for all Asset Health for all equipment
Asset Health Reporting None None exists on high criticality route-based equipment including Mechanical, Electrical
equipment and Stationary
Informal FMEA on limited Formal FMEA performed FMEA utilized on 65% FMEA performed on 80% of
Failure Mode Analysis None equipment types on 50% of assets of assets and used for assets and integrated with Life
program optimization Cycle Cost and Weibull Analysis
Limited but using cost and Integration of operational Using OEE, Life Cycle Cost,
Analytical Methods None Informal, limited capability work order trending to measurements, asset health, RCMs completed on 80% of
based on experience develop action lists and RCM completed on 50% plant systems
of plant systems
Some formal RCA based Triggers in place (e.g. cost, Triggers refined, many
Investigations rarely happen on high cost failures, limited # of failures, operational employees including operations
Failure Investigation Informal and are not documented # of employees formerly involvement, etc.), RCAs are trained in RCA, metrics in place
trained in RCA documented and published to measure results, willingness to
incorporate OEM experts
ROI Negative to Zero Minimal to no ROI 4:1 8:1 16:1
% Failure Maintenance >70% >50% <40% <25% <15%
RESULTS / /SCORECARDS
>50% Overall >65% Overall >80% Overall
Results Scorecards
PM/PdM Balance <25% Overall <35% Overall 15% PdM 25% PdM 45% PdM
35% PM 40% PM 35% PM
Exists on critical assets Exists on all assets Exists on all assets
Asset Health Not measured Not measured
> 65% Green >75% Green >80% Green
Route Adherence Not measured <50% >70% >85% >90%
% PdM Recommendations
Implemented <15% <30% >50% >75% >90%
Helping companies build wealth and competitive advantage through
world-class reliability across a global manufacturing network.
Allied Reliability Inc.
4360 Corporate Rd, Suite 110 | Charleston, SC 29405
o. 888.414.5760 | f. 843.414.5779 | www.alliedreliability.com