Repair vs Replace Decision Matrix

Executive Overview

A weighted comparison tool for the repair-vs-replace decision, formalizing the general framework already published in the Handbook into a fillable matrix an engineer can apply to a specific machine.

Purpose

Repair-vs-replace decisions are often made on gut feel or budget pressure alone. This matrix exists to make the underlying factors explicit and weighed consistently, so the recommendation is traceable to stated reasons rather than an unstated judgment call.

When to Use

• After a Recovery Assessment Worksheet has determined the technical recovery level
• When the technical finding alone doesn't resolve the business decision (e.g., a technically repairable machine that's also near obsolete)

Classification

Required Inputs

• Recovery Assessment Worksheet result (technical recovery level)
• Estimated replacement lead time and cost
• Estimated recovery cost (via the Recovery Scope Estimator)
• Operational criticality of the asset

Expected Outputs

A scored comparison supporting a repair or replace recommendation, with each contributing factor visible rather than hidden inside a single verbal judgment.

The Matrix

Procedure

1. Fill in the "This Case" column for each factor based on actual findings, not assumption.
2. Where a factor doesn't clearly favor either side, state that explicitly rather than forcing a lean.
3. Weigh operational criticality alongside the matrix — a technically marginal repair may still be justified for a non-critical asset with a long lead time on replacement.
4. State the final recommendation with reference to which factors drove it.

Acceptance Criteria

Engineering Notes

Typical Mistakes

Related Content

Future Download Formats

The web version above is fully usable today. Downloadable formats follow in a future release.

Revision History