Every maintenance department strives to become a world-class organization where optimal and efficient work is done. Worldwide maintenance or World-class maintenance (WCM) revolves around anticipating future failures and turning all repairs and interventions into planned activities to avoid failures at all costs.
To achieve WCM, maintenance management must undergo a cultural and attitudinal shift. The approach requires a focus on high-level planning and prevention supported by specialized computerized maintenance management systems (CMMS) such as SAP, Infomante or Valb CMMS.
With a CMMS, organizations can achieve their predetermined goals and ensure that all necessary work is carried out with the utmost scientific rigor.
- 1 Objectives of the WCM
- 2 World Class Maintenance Management
- 3 Worldwide Maintenance Standards
- 3.1 Interdisciplinary team focus
- 3.2 Integration with suppliers
- 3.3 Productivity-oriented contractors
- 3.4 Support and vision of management
- 3.5 Proactive planning and programming
- 3.6 Processes for continuous improvement
- 3.7 Disciplined management for the acquisition of materials
- 3.8 Systems integration
- 3.9 Disciplined management of maintenance stops
- 3.10 Production based on reliability
Objectives of the WCM
The goals of a worldwide maintenance organization can be summarized in the following list:
- Quality and profitability of products.
- Meeting production requirements.
- Maximum reliability.
- Excellence in core processes.
- Maximum environmental protection.
- Maximum personal safety.
- Motivation, personal satisfaction, and customer satisfaction.
Continuous improvement in all aspects of production is a key focus of worldwide maintenance, with top management playing a critical role in motivating and engaging all employees at every level.
World Class Maintenance Management
Implementing world-class maintenance (WCM) requires a change in attitude and culture towards the customer, especially in the production area, and is supported by a computerized information system.
The objectives of WCM include maximizing reliability, achieving required production, and ensuring quality and profitability of products.
To implement this tactic, companies should focus on planning, prevention, scheduling, anticipation, reliability, analysis of production losses, and spare parts management.
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It’s important to note that the results of WCM are not immediate, and implementing such changes can take a long time and require extensive training of employees.
It’s crucial to have a high level of commitment from all parties involved to ensure the success of the implementation process. Companies that export products or services must adapt to local standards where they are sold.
Multinational companies are typically the ones that implement WCM tactics, based on international laws such as SAE, ISO, DIN, and British Standard.
The emphasis on continuous improvement in all aspects of production is a motivating factor, and top management support is essential for motivating all levels of the organization.
Worldwide Maintenance Standards
These are the 10 practices that underpin a world-class maintenance system:
Interdisciplinary team focus
Organize teams with different skills and backgrounds to foster comprehensive analysis of processes and find the best solutions.
Integration with suppliers
Manage spare parts inventory with suppliers to reduce costs for old or obsolete inventories.
Contractors should be treated as strategic partners and encouraged to contribute to improving production.
Support and vision of management
Top management must support and provide tools for continuous improvement, including training and incentive programs.
Proactive planning and programming
Planning and programming must be organized and methodical to maximize effectiveness and increase equipment availability.
Processes for continuous improvement
Intense and constant search for improvement should be promoted and recognized by management to establish a culture of continuous improvement.
Disciplined management for the acquisition of materials
Standardize spare parts and materials to find better acquisition costs and allow for better negotiations and delivery times.
Standardize data processing systems to improve communication and decision-making between different areas.
Disciplined management of maintenance stops
Treat maintenance stops with a similar emphasis to managing a project, with clear schedules and sufficient planning to avoid unforeseen events.
Production based on reliability
Establish specialized groups of maintenance engineers to apply predictive maintenance techniques to anticipate premature or sudden failures.