Fleet Maintenance

Step 1.3 -- Regulatory Framework

Identify compliance implementations:

• FMCSA regulations (49 CFR Parts 390-399)
• DOT annual inspections (49 CFR 396.17)
• Driver Vehicle Inspection Reports (DVIR per 49 CFR 396.11-13)
• Electronic Logging Device (ELD) mandate (49 CFR 395)
• Brake inspection requirements (49 CFR 396.25)
• Emissions compliance: EPA, state programs like CARB
• OSHA shop safety

Step 1.4 -- System Integrations

Map external connections:

• Telematics platforms: Geotab, Samsara, Verizon Connect, CalAmp
• ERP/finance systems
• Fuel card providers: WEX, Comdata, Fuelman
• Parts suppliers: NAPA, AutoZone Fleet, Genuine Parts
• Tire management: Michelin, Bridgestone
• Fleet management information systems: AssetWorks, RTA, Fleetio, Dossier

============================================================ PHASE 2: PREVENTIVE MAINTENANCE SCHEDULING

Step 2.1 -- PM Program Structure

Evaluate:

• PM schedule types: time-based, mileage-based, engine-hour-based, condition-based
• PM levels: A-service/minor, B-service/intermediate, C-service/major
• Manufacturer recommended intervals vs. fleet-customized intervals
• PM task lists by vehicle class and age
• PM schedule optimization: grouping tasks to reduce shop visits

Step 2.2 -- PM Compliance Tracking

Check for:

• PM compliance rate calculation (completed on time / scheduled)
• Overdue PM alerts and escalation
• PM forecasting: upcoming PM events by week/month
• Seasonal PM adjustments: winterization, summer cooling checks
• PM deferral documentation and approval workflow

Step 2.3 -- Condition-Based Maintenance

Assess:

• Telematics-triggered maintenance: fault codes, DTC analysis
• Oil analysis programs: trend monitoring, sample scheduling
• Tire tread depth and pressure monitoring
• Battery health monitoring
• Predictive maintenance models: remaining useful life estimation
• Condition monitoring thresholds and alert configurations

Step 2.4 -- PM Effectiveness

Evaluate:

• Breakdown rate correlated with PM compliance
• PM interval optimization: are intervals too frequent or too infrequent?
• Component failure patterns relative to PM timing
• Cost comparison: PM cost vs. breakdown repair cost
• PM program ROI calculation

============================================================ PHASE 3: PARTS INVENTORY AND FORECASTING

Step 3.1 -- Parts Inventory Management

Evaluate:

• Parts catalog: part numbers, descriptions, vehicle applications, supersessions
• Inventory tracking: quantity on hand, reorder point, reorder quantity, bin location
• Inventory valuation method: FIFO, LIFO, average cost
• Multi-location inventory
• Core return and warranty parts tracking
• Obsolete parts identification

Step 3.2 -- Parts Forecasting

Check for:

• Demand forecasting: historical usage, PM schedule-driven, seasonal patterns
• Safety stock calculations: service level vs. holding cost optimization
• Vendor lead time tracking
• Economic order quantity (EOQ) or min/max models
• Critical parts identification: high failure impact, long lead time
• Fleet age-driven demand curves

Step 3.3 -- Procurement Integration

Assess:

• Approved vendor catalogs with negotiated pricing
• Electronic ordering: punchout catalogs, EDI
• Purchase order automation for reorder points
• Price comparison across vendors
• Contract compliance monitoring
• Emergency parts sourcing workflow

Step 3.4 -- Parts Cost Analysis

Evaluate:

• Parts cost as percentage of total maintenance cost
• Cost per mile by parts category
• OEM vs. aftermarket analysis
• Warranty recovery tracking
• Core return recovery rate
• Inventory turnover ratio
• Carrying cost calculation

============================================================ PHASE 4: DOWNTIME MINIMIZATION

Step 4.1 -- Downtime Tracking

Evaluate:

• Vehicle downtime recording: shop time, parts waiting, vendor waiting, scheduled PM
• Downtime reasons categorization
• Vehicle availability rate calculation (uptime / total fleet days)
• Mean time between failures (MTBF)
• Mean time to repair (MTTR)
• Planned vs. unplanned downtime ratio

Step 4.2 -- Shop Operations

Check for:

• Work order lifecycle: open, in progress, waiting parts, waiting vendor, complete
• Technician scheduling and workload balancing
• Shop bay management
• Priority queue for critical vehicles
• Repair time estimation: flat rate, historical average
• Job costing: labor hours, parts, outside services

Step 4.3 -- Outsource Management

Assess:

• Vendor repair authorization workflow
• External repair cost tracking
• Vendor performance scoring: quality, turnaround, cost
• Warranty coordination with dealers and OEMs
• Towing and roadside service management
• Mobile repair service utilization

Step 4.4 -- Spare Vehicle Management

Check for:

• Spare pool sizing (% of fleet)
• Spare vehicle assignment workflow
• Rotational spare programs
• Spare utilization tracking
• Spare vehicle maintenance standards: kept road-ready
• Cost impact of spare fleet size on availability targets

============================================================ PHASE 5: TOTAL COST OF OWNERSHIP (TCO)

Step 5.1 -- TCO Model

Evaluate:

• Cost components tracked: acquisition, financing, fuel, maintenance, insurance, registration, depreciation, disposal
• Cost allocation: per vehicle, per mile, per hour
• Lifecycle cost tracking from acquisition to disposal
• Depreciation method: straight-line, declining balance, usage-based
• Residual value estimation

Step 5.2 -- Replacement Analysis

Check for:

• Replacement criteria: age, mileage, maintenance cost threshold, condition score
• Optimal replacement point calculation: minimizing lifecycle cost per mile
• Replacement forecasting and capital planning
• Fleet age profile analysis
• Vehicle specification optimization: right-sizing for mission

Step 5.3 -- Benchmark Comparison

Assess:

• Cost-per-mile benchmarks by vehicle class
• Comparison against industry benchmarks: NAFA, AFLA, Mercury Associates
• Peer fleet comparison capability
• Year-over-year cost trend analysis
• Cost driver identification: what is causing cost increases

============================================================ PHASE 6: TELEMATICS AND DATA ANALYTICS

Step 6.1 -- Telematics Integration

Evaluate:

• Data points collected: GPS, speed, RPM, fuel level, fault codes, idle time
• Data transmission frequency and latency
• Telematics-to-maintenance system data flow
• Diagnostic trouble code (DTC) interpretation and work order generation
• Odometer synchronization: telematics vs. manual reads

Step 6.2 -- Predictive Analytics

Check for:

• Failure prediction models: component-level
• Maintenance cost forecasting
• Fleet reliability trending
• Anomaly detection: unusual fuel consumption, operating patterns
• Remaining useful life models for major components: engine, transmission, brakes

Step 6.3 -- Reporting and Dashboards

Assess:

• Maintenance KPI dashboards: PM compliance, availability, cost per mile, MTBF
• Management reporting: fleet summary, aging, cost trends
• Technician productivity reports
• Vendor performance reports
• Regulatory compliance reports
• Ad-hoc query and export capabilities

============================================================ PHASE 7: WRITE REPORT

Write analysis to docs/fleet-maintenance-analysis.md (create docs/ if needed).

Include: Executive Summary, PM Program Effectiveness, Parts Management Assessment, Downtime Analysis, TCO Model Review, Telematics Integration, Regulatory Compliance Status, Recommendations with projected cost impact.

============================================================ SELF-HEALING VALIDATION (max 2 iterations)

After producing output, validate data quality and completeness:

1. Verify all output sections have substantive content (not just headers).
2. Verify every finding references a specific file, code location, or data point.
3. Verify recommendations are actionable and evidence-based.
4. If the analysis consumed insufficient data (empty directories, missing configs), note data gaps and attempt alternative discovery methods.

IF VALIDATION FAILS:

• Identify which sections are incomplete or lack evidence
• Re-analyze the deficient areas with expanded search patterns
• Repeat up to 2 iterations

IF STILL INCOMPLETE after 2 iterations:

• Flag specific gaps in the output
• Note what data would be needed to complete the analysis

============================================================ OUTPUT

Fleet Maintenance Analysis Complete

• Report: docs/fleet-maintenance-analysis.md
• Vehicle classes analyzed: [count]
• PM compliance rate: [percentage]
• Fleet availability rate: [percentage]
• Cost per mile: [$amount]

Summary Table

NEXT STEPS:

• "Run /fuel-optimization to analyze fuel consumption patterns across the fleet."
• "Run /fleet-safety to evaluate driver behavior and accident risk factors."
• "Run /vehicle-routing to optimize routes considering vehicle maintenance windows."

DO NOT:

• Do NOT modify any maintenance schedules, work orders, or parts inventory records.
• Do NOT recommend extending PM intervals without failure data analysis to support the change.
• Do NOT ignore FMCSA/DOT compliance requirements even for non-CDL vehicle classes.
• Do NOT skip telematics data quality assessment -- bad data drives bad maintenance decisions.
• Do NOT assume spare fleet sizing without analyzing actual availability requirements.

============================================================ SELF-EVOLUTION TELEMETRY

After producing output, record execution metadata for the /evolve pipeline.

Check if a project memory directory exists:

• Look for the project path in ~/.claude/projects/
• If found, append to skill-telemetry.md in that memory directory

Entry format:

### /fleet-maintenance — {{YYYY-MM-DD}}
- Outcome: {{SUCCESS | PARTIAL | FAILED}}
- Self-healed: {{yes — what was healed | no}}
- Iterations used: {{N}} / {{N max}}
- Bottleneck: {{phase that struggled or "none"}}
- Suggestion: {{one-line improvement idea for /evolve, or "none"}}

Only log if the memory directory exists. Skip silently if not found. Keep entries concise — /evolve will parse these for skill improvement signals.