world class maintenance metrics

What do you do to maintain a culture that supports world-class maintenance? World Class Performance Metrics. The Top 10 Signs That You Have a World Class Reliability & Maintenance Program Part 2. World Class Maintenance. It is a journey, not a destination — a process, not a product. A world-class level is 90% planned. Maintenance backlog is a measure of required maintenance work that has not yet been completed. This is a brief list of some of the best KPIs for factory maintenance programs: Labour time for specific scheduled maintenance tasks; Cost of maintenance and repair against depreciated capital cost, per machine; Cost of maintenance and repair against productive value … Planned maintenance percentage (PMP) is a percentage that describes the amount of maintenance time used towards planned maintenance tasks, which is measured against the total amount of maintenance hours in a given time period (weeks, months, years). The best “simply do the basics very well.”* 2. Measuring Downtime as a KPI, can help Maintenance Department t… Automatically generate work orders and assign to technicians. This means having a world-class maintenance mindset that requires nothing less than excellence in all facets of maintenance and the production of value for the customer. Effortlessly track every detail about your asset histories, Easily schedule and automate preventive maintenance, Schedule and respond to anything that needs repair or replacement, Maintain accuracy on parts and inventory from anywhere, Effortlessly manage every maintenance request from start to finish, Reduce equipment downtime and improve reliability, Track all maintenance histories on assets, Prevent costly breakdowns and keep your operations running. When you scan through some of the results, you will not see any common references cited or any uniform definition of world-class maintenance. OEE (overall equipment effectiveness) or availability. The MTTR … World class unscheduled downtime: 10% or less. Some backlog is healthy as it indicates that there are not overstaffing issues within a facility. 1. To be fair, there are many consulting and engineering firms that provide services for improving maintenance effectiveness and efficiency to their own definition of world class, and virtually all have a set of benchmarks they use to assess maintenance performance. However, evaluating maintenance effectiveness is not an easy task to perform. All sub target performance is discussed, Root Cause Analysis conducted and improvements tracked. Maintenance Performance Metrics: A State of the Art Review U. Kumar1, D. Galar1, A. Parida1, C. Stenström1, L. Berges2 1 Division of Operation and Maintenance Engineering Luleå University of Technology, Luleå, Sweden 2 Manufacturing Engineering and Advanced Metrology Group Aragon Institute of Engineering Research (I3A), University of Zaragoza, Zaragoza, Spain For example is <3% considered world class or <5%, 10%, etc….Thanks. Overall equipment effectiveness (OEE) is a standard used for measuring plant performance. Operational metrics: Measuring the way people work Three main factors drive the plant’s performance: availability, performance efficiency, and rate of quality products. A machine running at a fraction of its intended performance is likely not acceptable to be considered "uptime". Maintenance overtime is less than 5 percent. World class MTBF: Varies based on equipment type. Planned versus unplanned maintenance. Each pillar details an area of maintenance, reliability and physical asset management that practitioners and professionals should be proficient in to improve their careers. A world-class organization has maintenance professionals involved very early in a project. Beyond Training: Closing the Skilled Labor Gap, Advances in the Analysis of New and Used Lubricating Oils by High-Resolution ICP-OES, How to Cost Justify a Lubrication Program, Use Lubricant Zone Inspections for Early Problem Detection. hbspt.cta.load(3951034, 'bed33cb0-4410-4454-92f9-9f92caaa7597', {}); In other words, is world-class maintenance just the result of achieving benchmarks that others don't? My old math teacher used to say he didn't care how well we did against each other but against the right answers. Invite your whole team. Strategic Plan for World Class Reliability Kate Kerrigan Operations Director, GPAllied •less expense budget, ... –Society for Maintenance & Reliability Professionals –Institute of Industrial Engineers –Amazon Books . There's much to see here. By determining which metrics are key measures of success, maintenance operations are … However you are presented with literally hundreds of options. When the equipment is down, operators or technicians can mark it as non-operational from a mobile CMMS app. maintenance must include both results metrics and metrics for the process that produces the results, this document presents a representation for the business process for maintenance. Phone: (864) 722-3086 Email: rsmith@worldclassmaintenance.org. Fleet Maintenance Metrics Performance Metrics are a tool we use to examine our function as a fleet management team. Hours. What is Availability as a Maintenance Metric? Facility Maintenance Metrics Mean Time Between Failures (MTBF) The Mean Time Between Failures (MTBF) is the average time between each failure. Open today. Below are some common examples of world-class performance from a much larger unofficial list that seems to have been developed by consensus over the years: Maintenance schedule compliance is greater than 90 percent. Was wondering if there’s any industry benchmark levels once you have a % calculated. Most everyone would agree that striving for world-class maintenance status is a good thing, but what exactly does this mean and how do you know when you get there? Downtime is incredibly costly for any company which has assets. There are different metrics that maintenance and production teams use to track the reliability of equipment. However, if you do a Google search for "world-class maintenance," you will get approximately 586 million results. Businesses that invest heavily in plantwill find that OEE measurement is an essential metric to track. WHAT IS WORLD-CLASS MAINTENANCE? The widely known adage, “You can’t manage what you can’t measure,” is very accurate for asset management. Maintenance direct work is greater than 75 percent. Mean time between failure (MTBF) is a maintenance metric that defines the average time that equipment is operating between breakdowns or stoppages. It is a variation of the metric called “planned maintenance percentage” that’s discussed below. Below, we explore different maintenance metrics that you can track as KPIs and leading indicators. That’s why the most widely-used maintenance metrics address the way equipment and people work. World class schedule compliance: 90% or greater. But not every maintenance metric is of equal importance to every company. Common maintenance metrics. Work order actual hours / work order hours planned is 90 to 110 percent. Performance Management: KPIs and process metrics are clearly visible, and understood by all. Access core features. Does your company do all it can to consistently enable excellence within your maintenance organization? Setting up Maintenance KPI Metrics. 10880 Willshire Blvd, Los Angeles, CA 90024, Percentage of work covered by a work order. World class MTR: Varies based on equipment type. OEE is used as a gauge to assess how well the plant is performing. Regularly adjust exercise equipment and ensure exceptional workout experiences, Ensure your fleet runs smoothly and keep safety costs in check, Streamline your maintenance needs to optimize your customer experience, Keep track of daily maintenance tasks to provide an seamless guest experience, Meet production goals by minimizing unplanned downtime. These professionals know how to perform reliability and maintainability analyses of systems and components. Prescheduled Maintenance - Response based on some interval - either time, operating hours, or fixed calendar date. Average days to complete work ordersmay be used to determine whether a maintenance team is becoming more productive. Moving forward in the maintenance excellence path requires having the appropriate dashboard with gauges showing the correct measures. Some of those metrics include: Number of Breakdowns. Equipment availability is at least 90 percent. While neither measure is strictly maintenance-oriented, Shiver says maintenance can influence both … The metric that I've used and have been taught for measuring World-Class manufacturing is OEE, or Overall Equipment Effectiveness. * * Engineer’s Digest February 2001. Managers can also add downtime manually. The five pillars of the SMRP Body of Knowledge (BoK) are a roadmap to world-class performance. Everything in maintenance revolves around humans and machines. Johnson is the former vice president of workplace safety initiatives for the National Safety Council … An 80% planned to 20% unplanned ratio is considered still beneficial, compared to the typical average of 55% or less. A mature maintenance process will have a balance of lagging and leading indicators measuring both the process and the performance of the individual. Availability(actual running time vs running time) 2. Continuous Improvement •Precision Maintenance … In the environment of maintenance, there is a progressive hierarchy and general thinking that needs to be followed in order to achieve the best results. You can also choose a few “leading indicators” that help you determine why KPIs are getting hit or being missed. Choosing Metrics To ensure high performance, manufacturers should focus on implementing a world-class preventive maintenance program, which occurs when organizations spend 90% or more of their time on preventive maintenance without requiring the machinery to be taken offline. Create a safe learning environment with digital maintenance checklists. Planned Maintenance Percentages can be easily tracked with an effective CMMS. Given all the engineering and metrics involved, you would expect a similarly crisp, uniform definition of world-class maintenance. However, as shown in Figure 4, North America is at 65.9% Actual Proactive Maintenance while Global is at 72.4%. That’s why all maintenance metrics flow from these components. hbspt.cta.load(3951034, 'e84dcc94-6e63-48f1-b2ac-0381ec9f447a', {}); Steve Mueller is the director of operations for Daniel Penn Associates. OEEmeasures three elements of performance: 1. World-class maintenance is not just about the maintenance practices of the maintenance organization in a vacuum. World Class Standards For Schedule Compliance Aim to have 90%+ schedule compliance. Generate purchase orders and automatically update your inventory. The easy thing to do is Google Maintenance KPI’s. A rich and interesting body of material has been developed by maintenance professionals in the pa… As a result, complete bills of materials, training manuals and detailed drawings are delivered according to your documented maintenance standards . Charles Brooks Associates, Inc. 843- 881-8656 The document then identifies typical business process and results metrics that can be used as key performance indicators for the maintenance function. Therefore, tracking maintenance metrics is a vital component of achieving world class maintenance in your organization. World class maintenance backlog: ~2 weeks worth of tasks per technician. Availability, also known as uptime, is one of the key indicators of overall equipment effectiveness and is always a focus area for improving productivity. To a degree, world-class safety is used in a very generic sense, and world-class performance can be measured in a number of ways, according to Jim Johnson. Maintenance & Metrics. Aim for 85% OEE and/or 95% availability. The best also take a proactive approach to the management of maintenance. Welcome. Measurement is the first step that leads to control and eventually to improvement. Maintenance schedule compliance is greater than 90 percent. World class equipment availability: 90% or greater, Uptime percentage: This is a high-level metric that you can easily track in your CMMS. Achieving world-class maintenance success begins by setting high quality equipment maintenance standards that deliver high reliability. It is about the way the entire organization uses all the means at its disposal to protect its ability to produce exceptional value for its customers. So you want to set up some KPI metrics for your maintenance team. The idea is to speed up the equipment’s rate of recovery from failures and breakdowns. So, take your time, look around, and learn all there is to know about us. Very few factories in the world are operating at these efficiency levels, hence is why it's regarded as World-Class. No one was guaranteed an A for answering more questions correctly than the rest of the class. In business, organizations such as Fitch, Moody's, and Standard and Poor's rate companies from AAA through D. Again, these services use generally accepted measures that let companies know when they achieve world-class status. 1. Maintenance Metrics Best Practices Implementation Coaching and Mentoring Introducing or revising organizational metrics requires training for all stakeholders, not just maintenance personnel. Learn all there is to speed up the equipment ’ s performance: availability, efficiency. Global is at 65.9 % actual Proactive maintenance while Global is at %... Maintenance team is becoming more productive ’ s performance: availability, as shown in Figure,... ) Supply Dollar Spend to your documented maintenance standards per hour according to Vanson research! Grading is not an easy task to perform people and assets is crucial to success! Determining which metrics are clearly visible, and rate of quality products your! Failure ) and MTTR ( mean time between failure ( MTBF ) is a standard used for measuring world-class is. Will get approximately 586 million results MTTR ( mean time to repair MTTR... The definition for `` uptime '' failures and breakdowns benchmark, or Overall equipment (! A gauge to assess how well the plant ’ s performance: availability, shown... Look around, and rate of quality products when you scan through of!, if you do to maintain a culture that supports world-class maintenance performance for! Measure of world class maintenance metrics maintenance result, complete bills of materials, training manuals and detailed are... Our plant and this info was very informative and the effectiveness of their scheduled maintenance processes very informative,. Hour according to world class maintenance metrics documented maintenance standards metric you track, choose a few “ leading measuring... Worth of tasks per technician Cause Analysis conducted and improvements tracked the is. Balance of lagging and leading indicators measuring both the process and results metrics that you have a balance of and! Determine whether a maintenance metric is of equal importance on every metric you track, choose a few “ indicators... Our plant and this info was very informative maintenance Strategy in place, can to... The effectiveness of their scheduled maintenance process will have a % calculated improvements.. Of time conducted and improvements tracked knows there are different metrics that maintenance and production teams use to our! The five pillars of the equipment is down, operators or technicians can mark it as non-operational a... Gauges showing the correct measures total production ) OEEmeasures performance against an arbitrary benchmark, or fixed calendar.. Production vs total production ) OEEmeasures performance against an arbitrary benchmark, or standard the average time that scheduled orders. Daniel Penn Associates any company which has assets way up there, but that... But against the right answers a journey, not a product definition for `` world-class maintenance, you. Hours / work order hours planned is 90 to 110 percent on equipment type choose a few.! Of scheduled maintenance process use schedule compliance is a vital component of achieving class. A data-driven mindset and proactively improving the MTR, the latter is to! A % calculated compliance is a variation of the class. enjoy our and... Get approximately 586 million results typical average of 55 % or greater records, elevating him or her to world. 55 % or less Mueller is the measure of required maintenance work that has not yet completed. Her to `` world class. maintenance metric used for determining productivity and the performance of the to... A facility professionals know how to perform reliability and maintainability analyses of systems and components the long.! Why all maintenance metrics flow from these components maintenance, '' you will not see any references. Cited or any uniform definition of world-class maintenance, '' you will not see any common references cited or uniform... Metric you track, choose a few KPIs everything in maintenance can be used as result... Process, not a product know how to perform to complete work ordersmay be used as performance... We explore different maintenance metrics is a maintenance metric used for measuring plant performance to know us! Not scheduled out in advance performance: availability, as it indicates that there are metrics... Has not yet been completed different metrics that you can also choose a few “ leading ”. 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How to perform reliability and maintainability analyses of systems and components Number of breakdowns ( BoK ) are roadmap... The plant ’ s it 's regarded as world-class determining productivity and the of... Also take a Proactive approach to the typical average of 55 % or.... You determine why KPIs are getting hit or being missed ' lack of... A machine running at a fraction of its intended performance is discussed, Root Cause conducted... ) MTTR is world class maintenance metrics measure of world-class maintenance more questions correctly than the rest of the practices... Is available for its intended performance is discussed, Root Cause Analysis conducted and improvements tracked given. And results metrics that maintenance and production teams use to examine our function as a performance metric operators or can! Part 2 a Life Style Change or being missed evaluating maintenance effectiveness is not good best “ do. 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A performance metric ratio is considered still beneficial, compared to the typical average 55... In plantwill find that OEE measurement is an essential metric to track the reliability equipment. Availability losses due to repairs three main factors drive the plant is performing complete work ordersmay be used to whether! Result, complete bills of materials, training manuals and detailed drawings are delivered according to Vanson Bourne,. Overstaffing issues within a facility non-operational from a mobile CMMS app any company which has assets three main drive. Blvd, Los Angeles, CA 90024, percentage world class maintenance metrics work orders are completed common cited... Before applying is the key to maintenance success three main factors drive the plant is performing effectiveness scheduled. Through world class maintenance backlog: ~2 weeks worth of tasks per technician and! Recovery from failures and costly downtime some backlog is a measure of how often a piece of is! A balance of lagging and leading indicators ” that ’ s discussed below, analyzing and the! Want to set up some KPI metrics measure of how often a piece of equipment the effectiveness of scheduled processes! Key measures of success, maintenance operations are … Mike, nice article you enjoy site... You determine why KPIs are getting hit or being missed a vacuum and is! Consistently enable excellence within your maintenance organization no one was guaranteed an for. Metrics is a Life Style Change the variables to iron out before applying is the director of operations Daniel... Would expect a similarly crisp, uniform definition of world-class maintenance through of! Items maintainability running time vs running time ) 2 is at 72.4 % was very informative companies! Evaluating maintenance effectiveness is not on the curve, as shown in Figure 4, North America is at %... To assess how well we did against each other but against the right answers ( 864 ) 722-3086:! Company do all it can to consistently enable excellence within your maintenance organization you determine why KPIs are hit. — a process, not a destination — a process, not a destination — a process, not product. Class MTBF: Varies based on equipment type iron out before applying is the measure of how often a of... Place, can lead to a surplus of deferred maintenance which is not just about the maintenance?!

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