# Maintenance and Reliability Maturity Self-Assessment > Source: https://netray.co/tools/maintenance-reliability-maturity-assessment > Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems. > Section: Free Tools ## Short answer Ten questions covering work management, preventive maintenance, spares, data and root cause practice, with a score and practical next steps. ## Category maintenance ## Audience - Maintenance manager - Plant manager - Reliability engineer ## Tool **Kind:** assessment **Questions:** #### How is maintenance work requested, approved and prioritised? **Options:** ##### Verbal requests, whoever shouts loudest goes first **Score:** 0 ##### Requests are written, but priorities are set ad hoc **Score:** 1 ##### Requests go through the CMMS with a defined priority scale **Score:** 2 ##### Defined priorities, a screening step and a weekly approved list **Score:** 3 #### How much of the maintenance hours are planned and scheduled in advance? **Options:** ##### Most work is reactive and done as it arrives **Score:** 0 ##### Some jobs are planned, schedules change daily **Score:** 1 ##### A planner prepares most jobs and a weekly schedule exists **Score:** 2 ##### Planner and scheduler roles, and schedule compliance is measured **Score:** 3 #### How are preventive maintenance tasks defined? **Options:** ##### No formal PMs, or PMs only from vendor manuals **Score:** 0 ##### PMs exist for key assets but have not been reviewed **Score:** 1 ##### PMs are in the CMMS with intervals and task lists, reviewed occasionally **Score:** 2 ##### PMs are based on criticality and failure modes and reviewed on a cycle **Score:** 3 #### How is PM completion tracked? **Options:** ##### Not tracked **Score:** 0 ##### Tracked informally by supervisors **Score:** 1 ##### PM compliance is reported monthly from the CMMS **Score:** 2 ##### Compliance is reported, with overdue PMs reviewed weekly and causes acted on **Score:** 3 #### How are critical spare parts decided and stocked? **Options:** ##### Stock is by habit or what was bought last time **Score:** 0 ##### Some critical spares are known by the old hands **Score:** 1 ##### Spares are linked to equipment bills of materials with min and max levels **Score:** 2 ##### Spares are set from criticality and lead time, with regular reviews of usage **Score:** 3 #### How good is the equipment and failure data in the CMMS or ERP? **Options:** ##### No reliable asset register **Score:** 0 ##### Asset register exists but history is incomplete **Score:** 1 ##### Asset hierarchy and breakdown coding are used on most orders **Score:** 2 ##### Consistent hierarchy, failure codes and costs, and data quality is audited **Score:** 3 #### How do you investigate significant failures? **Options:** ##### Fix and restart, no investigation **Score:** 0 ##### Informal discussion for major events only **Score:** 1 ##### A defined trigger and a standard method such as 5 Whys **Score:** 2 ##### Defined triggers, trained facilitators and tracked corrective actions **Score:** 3 #### Which maintenance KPIs do you review, and how often? **Options:** ##### None **Score:** 0 ##### Downtime or cost, occasionally **Score:** 1 ##### A monthly set including PM compliance, backlog and MTBF or MTTR **Score:** 2 ##### Leading and lagging KPIs reviewed weekly with actions assigned **Score:** 3 #### How are condition monitoring and predictive techniques used? **Options:** ##### Not used **Score:** 0 ##### Operator observations and occasional checks **Score:** 1 ##### Routes for vibration, oil or thermography on critical assets **Score:** 2 ##### Monitoring is feeding condition-based work orders with measured results **Score:** 3 #### How involved are operators in basic care of equipment? **Options:** ##### Operators only run the machines **Score:** 0 ##### Operators report problems when they see them **Score:** 1 ##### Operators do basic cleaning, inspection and lubrication on some assets **Score:** 2 ##### Autonomous maintenance standards are in place and audited **Score:** 3 **Bands:** #### Reactive **Min:** 0 **Max:** 30 **Verdict:** Most work is driven by breakdowns, and the data needed to improve is missing. **Recommendations:** - Clean up the asset register for your 20 most critical assets first - Introduce written work requests with a simple three-level priority scale - Start recording breakdown start and end times on every failure - Pick one repeat failure and run a 5 Whys investigation #### Developing **Min:** 31 **Max:** 55 **Verdict:** Basics exist but are applied unevenly, and planning and data still depend on individuals. **Recommendations:** - Assign a planner and protect planning time from firefighting - Review PM intervals and task lists for the critical assets - Start measuring PM compliance and backlog in weeks of work - Define failure codes and train technicians to use them #### Controlled **Min:** 56 **Max:** 80 **Verdict:** Planning, PM and data are working, and you can use them to decide where to improve. **Recommendations:** - Rank assets by criticality and use it to set PM and spares strategy - Move from calendar PMs to condition-based tasks where failures are detectable - Close the loop between failure analysis and PM changes - Track schedule compliance as well as PM compliance #### Proactive **Min:** 81 **Max:** 100 **Verdict:** Maintenance is planned, measured and improved from data. Keep the discipline and look for the next gains. **Recommendations:** - Audit data quality regularly so the numbers stay trusted - Use reliability analysis such as Weibull on repeat failures - Link maintenance data to production and quality to quantify impact - Share good practice between sites and review the strategy annually ## Content **Intro:** Maintenance improvement works best when you know where you are starting. This ten-question self-assessment covers the practices that usually separate reactive maintenance from a controlled, planned operation, and turns your answers into a level and a short list of next steps. **Sections:** #### How to use the assessment **Body:** Answer for what actually happens on an average week, not what the procedure says. Ideally have the maintenance manager, a planner, a supervisor and a technician answer separately, then compare. Large differences between answers are useful: they show where the system on paper and the practice on the floor have drifted apart. The score is a conversation starter, not a certification. **Bullets:** - Answer from observed practice - Compare answers across roles - Repeat every six to twelve months - Pick two or three actions, not twelve #### What is being measured **Body:** The questions cover work management, planning and scheduling, preventive maintenance, PM tracking, spare parts, data quality, failure investigation, KPIs, condition monitoring and operator care. These are the same building blocks used in common maintenance management frameworks. The order of improvement matters: planning and data foundations come first, because predictive techniques give little without reliable asset records and a planner to act on the findings. #### Reading your level **Body:** A reactive score does not mean poor people; it usually means few hours are protected from emergencies. Developing sites often have good PMs on paper but poor data. Controlled sites are ready to be selective: not every asset deserves the same strategy. Proactive sites should be wary of complacency and keep auditing data quality, since reports are only as good as the codes behind them. #### Common mistakes **Body:** Buying software before fixing the process is the classic error. A CMMS or ERP maintenance module will reproduce your current habits, good or bad. Another is chasing predictive tools while the PM list is out of date. Finally, avoid setting targets without definitions: say how PM compliance and backlog are calculated before comparing sites. **Cta:** If your result shows data as the main gap, we can talk about getting clean maintenance history out of your ERP and reporting on it on your own infrastructure. **Faq:** #### Is this a recognised standard maturity model? **Answer:** No. It is a practical self-assessment built from common maintenance management practices and is not tied to a certification scheme. Use it for internal discussion and to choose next steps, not for external claims. #### What score should we aim for? **Answer:** Aim for the next level, not the top. Moving from reactive to developing delivers large gains from small changes, such as a planner and written requests. Targeting the top band on every dimension at once rarely works. #### Does a high score mean we have low downtime? **Answer:** Not directly. It indicates good practices, which tend to reduce downtime, but results also depend on equipment age, duty and operating conditions. Track downtime and cost alongside the maturity score. #### Who should complete it? **Answer:** Several people from different roles: maintenance management, planning, supervision and technicians. Compare the answers. A gap between management and technician answers is itself a finding. ## Search terms maintenance maturity assessment, maintenance and reliability assessment, reactive vs proactive maintenance self assessment, maintenance management audit, maintenance best practices assessment, reliability maturity model, maintenance program self assessment, cmms maturity --- Talk to an engineer: https://netray.co/contact?intent=erp_ai | Machine catalog: https://netray.co/agent/catalog.json