Plan

Reliability Improvement 90‑Day Plan

A practical, fillable 90-day plan template to reduce unplanned downtime by addressing your top three assets or failure modes with clear baselines, prioritized actions, a condition-monitoring pilot, training needs, measurable KPIs, and a simple ROI/payback workflow. Designed as a working plan teams can save and iterate.

Interactive Tool

Reliability Improvement 90‑Day Plan

Use this working plan to focus 90 days of reliability activity on the top assets or failure modes that cause the most downtime and cost. Capture current baselines, specify priority actions, plan a short condition-monitoring pilot, identify training needs, set measurable targets, and estimate ROI so governance meetings can track progress. Save your responses so the team can iterate weekly.

Give this plan a concise name (e.g., 'Plant A – Crusher Reliability 90 Day').
Person accountable for driving the 90‑day plan.
List your top three assets or failure modes you will address and one short sentence why each is a priority (e.g., highest downtime, highest cost, safety risk).
Describe the typical failure (e.g., bearing failure, belt misalignment).
Average downtime attributable to this asset/failure mode in a typical month.
Estimated cost of that downtime (lost production, labor, expedited parts).
For each asset, capture planned actions such as: Clean & inspect tasks, spare parts ordering, update or create procedures, engineering fixes, and who will own each action. Use short action lines (one action per line).
Describe pilot scope: sensors or checks, sample frequency, who will collect data, initial duration (e.g., 8 weeks), and success criteria.
Enter the percentage availability you aim to reach for the targeted asset(s) by the end of 90 days.
Average mean time to repair for the asset/failure mode right now.
Mean time between failures baseline.
Schedule a short weekly meeting (15–30 minutes) to review status against the plan.
Recommended 15–30 minutes. Keep it focused on blockers, progress, and decisions.
List roles or names who must attend (e.g., Maintenance Supervisor, Reliability Engineer, Operations Rep).
Capture key deliverables for weeks 1–4 (actions, owners, dates).
Capture key deliverables for weeks 5–8 (actions, owners, dates).
Capture key deliverables for weeks 9–12 (actions, owners, dates).
One‑time implementation cost including parts, labour, contracted services. Leave 0 if none.
How many hours per month do you expect to save after interventions? Use conservative estimate.
Include lost production, labour, and other direct costs per hour.
Compute as: Expected downtime reduction (hours/month) × Cost per downtime hour. Enter the result here.
Compute as: Proposed intervention cost ÷ Estimated monthly savings. Enter the result here. If savings = 0, enter 'NA'.
List the main risks to plan success and assumptions behind your estimates (e.g., spare parts lead time, access windows).
Be specific and measurable (e.g., reduce downtime from X to Y hours/month, reduce emergency work orders by Z%).
Short list of what to do in the next 7 days and who will do it.
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