6 Key Elements of a Vehicle Maintenance Program

Customers that have a world class vehicle maintenance program share 6 key elements: operational planning, personnel and training, compliance management, parts management, recordkeeping, and preventive maintenance. J. J. Keller is here to help you make your maintenance program world class!

1. Operational Planning

  • Have a business plan containing the major objectives of the department.
  • Include all the major tasks that need to be completed.
  • Set goals that are specific, measurable, achievable, and realistic within a given time frame.
  • Make sure what gets measured gets done.
  • Identify who is responsible for what.
  • Determine the financial impact (good or bad) of the maintenance department and the operational plan.
  • Use the FMCSA’s Safety Management Cycle or another model based on the LEAN principle.

2. Personnel and Training

  • Recruit and retain qualified and certified technicians for annual/periodic inspections, brake inspections, and A/C repairs.
  • Provide initial training and retraining for mechanics and drivers.
  • Make sure drivers know who to call when there is a problem and how and when to submit documentation.
  • Allow drivers to ā€œred tagā€ equipment to alert other drivers and the maintenance team of needed repairs.
  • Celebrate success and share the savings. This need not be a ā€œbonusā€ program; it may simply take the form of gas cards or certificates that recognize when an associate contributes to high-level objectives by executing their role well.

3. Compliance Management

  • Stay abreast of DOT, OSHA, and EPA regulatory requirements and follow them.
  • Track every roadside violation and repair request. Watching these two data sets can indicate a problem with the maintenance program or a problem with specific equipment.
  • Post CSA scores in multiple visible areas of the company.

4. Parts Management

  • Know sources for parts (new, used, rebuilt, and remanufactured), and warranties.
  • Track your parts and supplies inventory, costs, and reorder points.
  • Report cost by vehicle, work performed, or per mile.
  • Compare repair expenses to revenues generated and use this information to establish replacement benchmarks for each piece of equipment.

Learn how to get better fuel economy.

5. Recordkeeping

  • Have an electronic system in place that issues alerts for preventive maintenance and annual inspections, and which tracks repairs, inventory, and costs.
  • Maintain DVIR records for all post-trip inspections, not just when a defect is found.
  • Consider eDVIRS for drivers with the use of an Electronic Logging Device.
  • Track mechanics' hours.
  • Inspection & Maintenance Recordkeeping

6. Preventive Maintenance

  • Consider quarterly preventive maintenance (PM) reviews. It pays to have a qualified mechanic take a deeper look more than once a year. This will be an investment in ā€œpeace of mindā€ and provide lower overall operational expenses.
  • Based on the needs of the company, determine PMs by time, miles, or engine hours.
  • Have an established schedule for trailers, lift gates, and other special equipment, as well as power units.
  • Have an ā€œinspection lane,ā€ which is a designated lane or shop where vehicles enter or exit the facility. Drivers can bring up complaints and have them checked on the spot.
  • In place of an inspection lane (which may be too expensive or cumbersome for every fleet), use yard checks." This involves having technicians, at specified times throughout the day, ā€œcruiseā€ the yard and check all equipment that is newly arrived in the yard.
  • Conduct random ā€œstakeoutsā€ at customers, lots, or fuel locations, to observe your drivers. Track how many drivers do the required inspections.
  • Conduct pre-service inspections on new equipment or equipment that has been inactive for a while.
  • Contact the Original Equipment Manufacturer (OEM) that built the vehicles. Most OEMs have an inspection and preventive maintenance (PM) schedule available for the vehicles they build.
  • Establish ā€œpull pointsā€ or ā€œcut-off points.ā€ This is a pre-determined ā€œwear and tearā€ threshold that, when reached, is the trigger for the part or component to be removed and replaced.

Learn more about creating a Successful Preventive Maintenance (PM) Program.