Plant Floor

Selected focus / Control

Reactive Work %What moves the number?

Start with control, not prediction. Unstable intake and scheduling will absorb every advanced tool you add.

Is demand being captured and controlled before it breaks into the week?

Reference target

Below 20% of maintenance labor hours

Use a consistent definition and your plant’s operating context.

The improvement path

Build the foundations.
Then move upstream.

Choose a stage. See what each system does, why it belongs, and the first action to take.

Stage 1 / Maturity 1

Capture demand

Make all work visible and rank what is waiting.

01 / Build this first

Work Order Management

What it does
If it's not in a work order, it didn't happen.
Why it matters here
Clean work requests make reactive demand visible before it becomes an emergency.
Your first move

Define minimum required fields: asset, priority, work type, description, completion notes

02 / Directly moves this KPI

Backlog Management

What it does
Know what's waiting — and why it's waiting.
Why it matters here
A ranked, aged backlog separates real risk from noise and gives planning a controlled queue.
Your first move

Export all open work orders from CMMS and categorize by priority, trade, and age

Build on: Work Order Management

Stage 1 of 4

Supporting layer

Useful after the foundations hold

Put Fix the System to work

One improvement. Three useful views.

Open the book’s worksheets
  1. 01Explore

    Choose the right tool

    Start with your role and the foundations your plant has in place.

    Maintenance Tool Roadmap
  2. 02You are here

    Trace what moves the KPI

    Find the supporting systems and the first change to investigate.

    KPI System Map
  3. 03Explore

    Give the change an owner

    Connect the result to a role measure, a practical action, and a review.

    KPI Cascade Framework

Use the book’s cycle and playbook picker to choose a response, then bring the relevant worksheet to the team. These connections guide an investigation; they do not prove a cause.

Need the KPI definitions?

Build the maintenance dashboard

Take the complete path with you

A visual pack for sharing. A field guide for working.

Share the two-slide overview, or bring the two-page PDF field guide to your next team review.

Substack

The weekly brief

Fix the System.

One practical maintenance systems essay every week. No gate, no consulting pitch.

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Fix the System book cover

The operating manual

Fix the System.

Chapter 3 maps the cycle. Chapter 14 selects the first playbook. Chapters 15–24 install the response behind the KPI.

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