Vee,
You hit it right on the head.
A majority of the programs that fail are a direct result of a loss of at least one piece of the puzzle.
I have been involved in one end, or the other, of RM&E for the past 20+ years. Some of the programs I have been involved in have been very successful, some have been disasters. I am glad to say that the majority have been successful, and have continued.
I have often found, also, that one of the most dangerous periods for the survival of any program is when it has finally, truly, started. That is the time when any new initiatives show much lower paybacks because all of the major problems have been resolved. You see, a successful maintenance program should have almost no room for payback. Unscheduled downtime, equipment failures, etc. are a measurement of the maintenance opportunity that directly results from a failure of proper maintenance in the past.
Problem is, that most businesses (let alone business schools - you know, the famous MBA stuff) generate a specific mindset and general business models that the typical MBA tries to apply to everything, including maintenance.
The result is, once a program becomes successful, it is seen as an expense: Why are we investing this much in maintenance when everything is running fine? Result: Maintenance Entropy. Management cuts the budget, personnel, etc. and things appear to run OK for about 12-24 months (lag).
Another area where I have seen failure comes from a lack of clear, direct, guidance for the program. I am, as a matter of fact, involved in trying to assist in turning around the program throughout a large manufacturer right now. Very little guidance for the program and buy-in from workers, outright hostility for the program from middle management. Supervisors and workers are looking for guidance and senior management wants it to happen. Fun stuff!
The challenge is, as has been mentioned, 'selling' the program to management, other departments, and the personnel who are involved. Unfortunately, most R&M types are not trained in sales.
Now, that I have rambled for a little, I will get off my soap box. I have just started a track on this subject in Terry's maintenance blogs in the motors section.
The more successful programs that I have been involved in have utilized either the complete RCM process or are 'RCM-based.' The individual application and goal for the client should guide the level of involvement (beware of cookie cutter solutions!).
When properly applied, RCM provides the logical rules and documented evidence of how and why you are performing the maintenance task. Coupled with periodic review of the maintenance program for adjustments and improvements due to new technologies, etc. and applicable metrics, the program should be quite successful.
[more in a little bit...]