The only way to reduce the cost of maintenance is to reduce the number of equipment failures. To reduce the number of equipment failures, maintenance productivity must improve. This means rigorous planning and scheduling of work, standardized procedures, reliability follow-up, high skill of workers, sophisticated supervision, incentivized behavior, and prideful workmanship using enabled, empowered workers. Repair and maintenance (R&M) budgets are based on historic spending. R&M budgets include systemic "common cause" (W. Edwards Deming) failures. These are failures that happened last year and in other years, and it's anticipated that they will happen in the future. The result is that there is little budgetary or managerial incentive to remove these failures from the system. Change becomes very difficult. Changing people's mindsets becomes a chore.
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