36th FVI Expert Breakfast

Topic: "Resilience in Maintenance" – How to extinguish fires before they start.

In this session, Dino Walter (Vaillant) presented his 5 pillars of resilient maintenance. The core message: Maintenance is not a cost factor ("Oily Fingers"), but a strategic pillar of value creation.

• Prevention instead of Reaction: Resilience does not arise from faster repairs, but from prevention. Dino demands: "Away from the firefighting mode." We need to know why something fails, not just that it fails.

• Criticality Matrix: Not every asset needs Predictive Maintenance. For unimportant assets (C-parts), "Run-to-Failure" is completely okay. But for A-assets (bottlenecks), a strategy is needed. Dino provocatively asked: "Who has a real criticality matrix?" Hardly anyone.
• Redundancy is not Waste: Dino mentioned the example of a calibration cart. If the only cart breaks down, production stops. A second cart costs money, but a downtime costs more. Redundancy creates security.
• Flexibility through Skills: Resilience also means that employees are flexibly deployable. If only one person can repair the asset and they are sick, you have a problem (head monopoly).
• Avoid Data Graveyards: Jörg (participant) warned against "checkbox lists". If employees only fill out forms to pass audits, quality decreases. Data must have a purpose. Dino added: "Key figures must be for maintenance, not about it (finger-pointing)."

Classification: Resilience through Systematics

This episode confirms our strategy of systematic data usage.

• Criticality in ADAM: ADAM allows you to classify assets by criticality (A/B/C). ADAM helps you differentiate your strategy. For A-assets, we activate Predictive Maintenance and AI monitoring. For C-assets, a simple fault report is sufficient. This way, you invest your budget where it has the greatest leverage (ROI).
• Knowledge Redundancy: Dino spoke of the danger of the head monopoly. ADAM creates redundancy in knowledge. If the expert is sick, thanks to the 'Digital Life Record' (where all repairs and tricks are stored), another colleague can repair the asset. This makes your maintenance resilient against personnel shortages.
• Data with Purpose: Dino demanded key figures that help, not judge. ADAM provides key figures like the 'First-Time-Fix-Rate'. This helps the team see: Where do we need retraining? Where are spare parts missing? We use data for improvement, not for control.

Conclusion: Resilience is not a coincidence, but the result of strategy. ADAM provides the data basis to operationalize this strategy (criticality, redundancy, knowledge).