The "Maintenance Insanity" Cure

Practical Solutions to Improve Maintenance Work

The “Maintenance Insanity” Cure
Practical Solutions to Improve Maintenance Work

Roger D. Lee


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“Practical and effective approaches to end the reactive maintenance vicious cycle that causes high cost, poor reliability, and burnout.”

“A smorgasbord of opportunities for maintenance improvement that can be implemented one at a time.”

“Written in an easy-to-use format, allowing readers to pick the specific topic of interest and get examples to follow.”



Einstein said that insanity is “doing the same thing over and over again and expecting different results.”  Yet that is exactly what is happening in maintenance organizations.  How many times have clients told consultants, “But we’ve always done it this way?!” 


In many companies, especially the large ones, we fail to talk to each other enough to know what needs to change to drive continual improvements and reduce waste.  This work will guide any size plant or organization to improve how they do maintenance, how to keep their equipment running longer, and create a more efficient and streamlined structure so they can be competitive in today’s market. The practical solutions offered in this work present the perfect antidote for maintenance insanity.


The book is chock-full of useful checklists, flowcharts, templates and other helpful documents that readers can customize for their own needs. These are available in black and white in the book, and in full-color versions on an affiliated website,

Roger D. Lee is the President and Founder of RDL Solutions, LLC, a general consulting firm that helps any size plant or company to improve efficiency, cost control, productivity and reliability.  They focus on leveraging the wisdom of experience to share learning’s gained and help the client change work processes to yield ongoing developmental advantages.  Solutions address organizational structure, assessments of present conditions, gap analysis with gap closure plans, behavior/result re-enforcement programs, cultural change processes and work process development.  RDL Solutions helps develop and drive client visions to become reality.  Lee has more than 42 years of experience in the chemical and refining industry with a huge variety of clients across the world.  


  • How Bad Are We?
  • Evaluate the Need for Intervention
  • The Maintenance Journey
  • Implementation
  • Planning and Scheduling Guiding Principles
  • Back to Basics
  • True Partnership
  • Small Site Planning and Scheduling
  • Cost Analysis
  • Contractor Productivity Improvement Process
  • Proper Team Structure
  • Continual Alignment Improvement Process
  • Assessment Processes and Cold Eye Review
  • Sales & Operations Planning
  • Mergers & Acquisitions
  • Shutdown/Turnaround Solutions
  • A Glimpse into the Future