January 30, 2025

Comprehensive Guide to MRRP: Understanding Maintenance Repair and Replacement Plans

When it comes to maintenance, you have two mindsets. Reactive and preventive. Reactive maintenance means you don't pay attention to the asset until something goes wrong. While many companies still operate this way, many more have understood the importance of prevention.

Take this a step further. Companies should develop a maintenance repair and replacement plan (MRRP) as part of their PJM strategy. In this article, we'll discuss the following:

• What Is an MRRP?
• Key Information to Include in Your MRRP.
• Step-by-Step Guide to Creating an Effective MRRP
• How CMMS Software Enhances Your MRRP

What Is an MRRP (Maintenance Repair and Replacement Plan)?

Many homeowners schedule preventive maintenance for their properties. Annual inspections of the HVAC and all aspects of the house. Roof, siding, foundation, gutters, etc. Consider this a basic MRRP.

For businesses, take that same concept, widen it to include all assets, and extend it out to ten years. When complete, you should have the answers to any inquiries.

Cite the expense figure for a new roof. How much will a new processor cost? Show me the annual estimated figures for a conveyor's PMs.

Yes, over ten years, you'd expect expenses to vary. Also, you need to keep in mind unplanned downtime, the unexpected. With an MRRP, though, you have a foundation from which to work. Plus, you have all assets and planned maintenance documented.

Remember the adage: "Proper preparation prevents poor performance." You make your MRRP to ensure the coverage of all aspects of future maintenance.

Key Information to Include in Your MRRP

What information should you include in this plan?

1. Your list of assets requiring PMs or that you'll replace in the next decade. Remember assets include not only equipment but structural holdings, too. Buildings, vehicles, etc.
2. Detail the current status of each of those assets.
3. Create regular maintenance cycles for assets. Estimate when you'll conduct maintenance activities on the others. Note which assets you'll replace. To evaluate this, you might use a depreciation scale.
4. Costs. Of parts, labor, replacement, etc.
5. The purpose of maintenance: To keep an asset at a baseline functionality. Using records, judge the lifespan of the assets.

Discover how streamlined maintenance processes can elevate production. Learn more.

The Benefits of Developing an MRRP

Why would you need such a plan?

1. Budgets and cost. You must consider maintenance an investment expense just as you do your assets. Looking ahead so far gives the company an idea of where to budget finances and resources.
2. Maintenance goals. You could set as one of your goals to reduce costs. Through an MRRP, you'll have a better oversight of where to tighten.
3. Clarity in company operations. Having an MRRP gives coworkers insight into company goals and expectations.
4. Reduced unplanned downtime. A rigorous PM plan includes the goals of extending asset lifecycles and reduce production interruption.
5. Compliance. With a plan in hand, you'll have documentation when regulators and auditors visit.
6. Reduced safety hazards. Focusing on PMs, you'll have better control over safety measures.

Step-by-Step Guide to Creating an Effective MRRP

How do you go about developing, establishing, and understanding a maintenance and repair plan?

1. Documentation. Create a list of your assets. Conduct a "current status" inspection for each. Note any that need readings tracking. Determine what PMs you'll need.
2. Check for parts and supplies to make sure you have sufficient quantities.
3. Cost analysis. Document the estimated costs of maintenance for the next decade for the assets. Prepare a schedule of all known activities.
4. Develop the plan. Take the above and convert it to a workable plan.
5. Communication. Discuss the plan with management and your maintenance team. Ask for feedback. See that the team has ample training opportunities if necessary.
6. Do it! One mistake of many projects and plans—failure to execute.
Given the chance, you could succumb to the temptation to make excuses why you should NOT begin. Don't fall into that trap. Commit and do!

How CMMS Software Enhances Your MRRP

How does a CMMS software benefit an MRRP?

1. Organization. The key fact for this plan and any other maintenance strategies you have. The system acts as a database for your records of assets, inventory, PMs, work orders, labor resources, and more. A quality system gives you easy access to reports and the current status of assets and work orders. No need for cumbersome spreadsheets and handwritten documentation.
2. Asset Management. You create your asset records in the system. Along with the PMs list, you match assets to PM procedures.
3. Inventory Management. Organize your stockroom for optimal resources. Quantities, location, and asset assignation.
4. Scheduling. You can schedule your work orders with a drag-and-drop method. View a segment of the calendar to see future jobs.
5. Reports. A CMMS offers plenty of reports on any information you input. This adds value to your program because you have compliance documentation ready.

Taking Control with an MRRP and CMMS

For a full understanding of maintenance and repair plans, you need time and effort. You need discussions with your team and management. You need the skills for cost analysis and insight for future activities.

Know your assets. Know your team. Know your resources. Use your experience to develop and execute a successful plan. Investing in the easy-to-use CMMS from Mapcon shows you know your stuff. Call 800-922-4336