Process & maintenance strategy
Criticality Management Matrix
Equipment classification & maintenance planning
0Equipment in register
0Critical (C0 + C1)
0High complexity (K0)
0Premium stock (A+ / A)
0Priority ≥ 80 · act now
0Past 80 % of expected life
Classification matrix
Criticality (consequence of failure) across, maintenance complexity down. Each cell sets the maintenance strategy and spare-parts policy. Select a tag to open its record.
Critical ≥ 80
High 60–79
Medium 40–59
Low < 40
Equipment register
Ranked by priority score. Select a row for the full record, radar analysis and QR tag.
Portfolio analytics
How the register splits across criticality, maintenance strategy and spare-parts policy.
Matrix population
Priority bands
Detailed distribution
| Category | Code | Count | Share | Equipment |
|---|
Classification reference guide
What each criticality level means, and the maintenance treatment and stocking policy it triggers.
| Criticality level | Code | Definition & driver | Strategy | Maintenance treatment | Spares | Stocking policy |
|---|---|---|---|---|---|---|
Safety / HSE-critical |
C0 | Failure poses immediate safety, health or environmental risk. Driver: HSE & compliance |
M0 Proactive & mandatory |
|
A High availability |
|
Process / production-critical |
C1 | Failure causes major production stoppage or severe loss. Driver: Production & profit |
M1 Preventive & predictive |
|
A/B Strategic stock |
|
Operational / non-critical |
C2 | Failure causes moderate disruption with a workaround available. Driver: Operational cost |
M2 Condition-based & reactive |
|
B/C Minimal / JIT |
|
Non-essential |
C3 | Failure has minimal to no impact on safety or production. Driver: Cost of repair |
M3 Reactive / run-to-failure |
|
C No stock / cannibalise |
|
Maintenance strategy codes
- M0+
- Proactive & mandatory, OEM-supported
- M0
- Proactive & mandatory
- M1+
- Preventive & predictive, OEM-supported
- M1
- Preventive & predictive
- M2
- Condition-based & reactive
- M3
- Reactive / run-to-failure
Spare-parts codes
- A+
- Premium stock — capital spares, duplicated
- A
- High-availability stock
- A/B
- Strategic stock, min/max
- B
- Moderate stock
- B/C
- Minimal / just-in-time
- C
- No stock / low stock / cannibalise
Abbreviations
- PM
- Preventive maintenance
- CBM
- Condition-based maintenance
- PdM
- Predictive maintenance
- MTTR
- Mean time to repair
- MTBF
- Mean time between failures
- VMI
- Vendor-managed inventory
- JIT
- Just-in-time
- GPS
- Team criticality assessment, 8 questions, 8–72 pts
How the priority score is calculated
The priority score (0–100) combines matrix position, the GPS team assessment, failure history and equipment age. It ranks the register and sets the priority band.
| Factor | Weight | Method | Points |
|---|---|---|---|
| Criticality (C) Consequence of failure | 40 % | C0 = 40 · C1 = 30 · C2 = 20 · C3 = 10 | 10–40 |
| Complexity (K) Difficulty of repair | 20 % | K0 = 20 · K1 = 15 · K2 = 10 | 10–20 |
| GPS team score 8 questions, 1 / 5 / 9 pts each | 25 % | GPS ÷ 72 × 25 (0 when not assessed) | 0–25 |
| Failure history Recorded failures | 10 % | 0–2 = 2 · 3–5 = 5 · 6–10 = 8 · >10 = 10 | 2–10 |
| Equipment age Share of expected life used | 5 % | <60 % = 1 · 60–80 % = 3 · 80–100 % = 4 · >100 % = 5 | 1–5 |
Worked example — P-101 centrifugal pump
C1 production 30
K0 high complexity 20
GPS 60 / 72 60 ÷ 72 × 25 = 20.8
7 failures 8 (6–10 range)
75 % of life used 3 (60–80 % range)
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Priority score 81.8 → CRITICAL
CRITICAL80–100 · immediate action
HIGH60–79 · schedule within 1 week
MEDIUM40–59 · plan within 1 month
LOW0–39 · routine maintenance