Maintenance Framework — 5 Pillars of Maintenance Excellence

The SMRP Framework

The SMRP 5-Pillar model is the gold standard for maintenance maturity assessment. Point-based scoring across 56 questions (max 280 pts) measures your organization against world-class maintenance practices.

Business & Management Strategic alignment, budgets, KPIs, organizational governance Q1 - Q12

60 pts

12 questions

Process Reliability RCM, PM optimization, failure analysis, process control Q13 - Q20

40 pts

8 questions

Equipment ReliabilityCORE Condition monitoring, precision maintenance, predictive analytics Q21 - Q33

65 pts

13 questions

Organization & Leadership Competency frameworks, training, culture of reliability Q34 - Q42

45 pts

9 questions

Work ManagementCORE Planning, scheduling, execution, work order lifecycle Q43 - Q56

70 pts

14 questions

Core pillars (heaviest weight)

Supporting pillars

Total: 280 pts

Maturity Scale (% of 280 pts)

Innocent

≤ 35%

›

Aware

36 - 50%

›

Developing

51 - 70%

›

TARGET

Competent

71 - 85%

›

Excellent

> 85%

The Reliability Iceberg

Reactive Costs What management sees

⚠ Breakdown repairs & emergency call-outs

⚠ Rush-ordered spare parts (10x premium)

⚠ Overtime & contractor surge labor

Waterline

Hidden costs (4-10x larger)

● Lost production & throughput penalties

● Quality defects & customer rejects

● Safety incidents & regulatory exposure

● Shortened asset lifecycle (premature replacement)

● Reputation damage & lost contracts

The Business Case

Cost Reduction 10-30% reduction in total maintenance cost through proactive reliability practices

PM Completion 95%+ planned maintenance completion rate in world-class organizations

PM Payback $1:$4 every $1 in PM saves $4 in breakdown repair costs

Emergency Premium 10× emergency repair costs 10x more than planned maintenance

Equipment availability improvement +20-40%

Safety incident reduction -50-70%

Energy consumption savings -5-15%

Asset lifecycle extension +25-40%