When the equipment is down, operators or technicians can mark it as non-operational from a mobile CMMS app. No one was guaranteed an A for answering more questions correctly than the rest of the class. Equipment productivity is at least 95 percent. It is a variation of the metric called “planned maintenance percentage” that’s discussed below. The document then identifies typical business process and results metrics that can be used as key performance indicators for the maintenance function. Create a safe learning environment with digital maintenance checklists. 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. ¾In any world class asset care program, you will find two things: As a result, complete bills of materials, training manuals and detailed drawings are delivered according to your documented maintenance standards . Mike, nice article. PdM - A maintenance response that will be scheduled based on reaching some predetermined condition of the equipment or process parameter being monitored. For instance, if schedule compliance is a KPI, “percentage of work covered by a work order” may be a leading indicator. 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. According to Vanson Bourne research, Average downtime costs 240.000 US dollars per hour according to decision makers in Field service and Service management. Continuous Improvement •Precision Maintenance … Of course, it would be great to be way up there, but should that be the only measure of world-class maintenance? Metrics that qualify as key performance indicators (KPIs) are dependent on your industry, your company’s goals, and the types of assets you manage. * * Engineer’s Digest February 2001. Everything in maintenance can be divided into two areas: people and assets. Equipment availability: This is a measure of how often a piece of equipment is available for its intended purpose. Schedule compliance measures the percentage of work orders completed on or before the due date over a given period of time. Measurement is the first step that leads to control and eventually to improvement. Operational metrics: Measuring the way people work 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 Data is collected from our fleet management software, and other sources, and translated into charts and graphs that illustrate trends, the … Schedule compliance is a maintenance metric used for determining productivity and the effectiveness of scheduled maintenance processes. Proactive Maintenance (100% - Reactive Maintenance) is about 70% and Perceived World Class is about 88% for the Top 20% companies (North America and Global). ), World class uptime availability: 90% or greater. Below, we explore different maintenance metrics that you can track as KPIs and leading indicators. The BoK forms the framework for all SMRP educational offerings and programs. There is no shortage of metrics, benchmarks and strategies to help keep you on the path of continuous improvement, but exceptional performance comes from being part of an organization that requires it. OEE (overall equipment effectiveness) or availability. Choosing Metrics Work order actual hours / work order hours planned is 90 to 110 percent. There are different metrics that maintenance and production teams use to track the reliability of equipment. Access core features. That’s why all maintenance metrics flow from these components. When you scan through some of the results, you will not see any common references cited or any uniform definition of world-class maintenance. The metric that I've used and have been taught for measuring World-Class manufacturing is OEE, or Overall Equipment Effectiveness. Maintenance direct work is greater than 75 percent. Johnson is the former vice president of workplace safety initiatives for the National Safety Council … Unscheduled downtime detracts from availability, as well as various types of preventive maintenance. The results companies are achieving from a World Class Manufacturing initiative are: 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. Provide world class guest service Preserve our nation’s treasures Be a world class educational institution ... • Perform the right about of maintenance at the right time. An athlete knows there are world records to beat because the records for any given event are measured in seconds, pounds or feet. Aim for 85% OEE and/or 95% availability. World Class Production through World Class Maintenance is a Life Style Change. 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. Therefore, tracking maintenance metrics is a vital component of achieving world class maintenance in your organization. So, take your time, look around, and learn all there is to know about us. OEEmeasures three elements of performance: 1. What do you do to maintain a culture that supports world-class maintenance? Mean time to repair (MTTR) MTTR is the measure of the repairable items maintainability. Automatically generate work orders and assign to technicians. A mature maintenance process will have a balance of lagging and leading indicators measuring both the process and the performance of the individual. OEE is used as a gauge to assess how well the plant is performing. A world-class level is 90% planned. The Top 10 Signs That You Have a World Class Reliability & Maintenance Program Part 2. Generate purchase orders and automatically update your inventory. Maintenance overtime is less than 5 percent. World class unscheduled downtime: 10% or less. World Class Standards For Schedule Compliance Aim to have 90%+ schedule compliance. World class maintenance notes that 90% of maintenance should be planned. The easy thing to do is Google Maintenance KPI’s. World-class maintenance is not just about the maintenance practices of the maintenance organization in a vacuum. 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. The best also take a proactive approach to the management of maintenance. 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. Planned maintenance work is greater than 90 percent. It is a journey, not a destination — a process, not a product. Quality(good production vs total production) OEEmeasures performance against an arbitrary benchmark, or standard. A focus on preventive maintenance benefits the organization in a number of ways. A rich and interesting body of material has been developed by maintenance professionals in the pa… 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. Achieving world-class maintenance success begins by setting high quality equipment maintenance standards that deliver high reliability. The benchmark for World-Class is 85% OEE (100% OEE means no losses at all). Hours. Charles Brooks Associates, Inc. 843- 881-8656 hbspt.cta.load(3951034, 'e84dcc94-6e63-48f1-b2ac-0381ec9f447a', {}); Steve Mueller is the director of operations for Daniel Penn Associates. Measuring Downtime as a KPI, can help Maintenance Department t… Planned Maintenance Percentage (PMP) Explained. 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. World class MTBF: Varies based on equipment type. Three main factors drive the plant’s performance: availability, performance efficiency, and rate of quality products. Some backlog is healthy as it indicates that there are not overstaffing issues within a facility. What if the grading is not on the curve, as it were? 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 . World Class Performance Metrics. 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 … This metric varies from process to process, and as bad as 22% Emergency Work may seem — and it is not a good number when compared with many world-class operations — the fact is that a large percentage of maintenance organizations actually do … World class MTR: Varies based on equipment type. Planned versus unplanned maintenance. KPI Metrics and eMaint CMMS However, evaluating maintenance effectiveness is not an easy task to perform. This time is calculated into the uptime percentage by the CMMS. Setting up Maintenance KPI Metrics. You can only improve what you measure. Maintenance & Metrics. World class equipment availability: 90% or greater, Uptime percentage: This is a high-level metric that you can easily track in your CMMS. Save money on early replacement costs and flag expiring warranties. A machine running at a fraction of its intended performance is likely not acceptable to be considered "uptime". Prescheduled Maintenance - Response based on some interval - either time, operating hours, or fixed calendar date. Managers can also add downtime manually. World Class Maintenance. Manage maintenance requests, assign work orders, and keep track of your assets, See how UpKeep helps maintenance teams achieve results, Supercharge productivity with mobile work orders, Reduce interruptions and manage requests with a single portal, Reduce parts costs with an accurate inventory count, Stay on top of maintenance schedules for every asset, Standardize your maintenance with itemized tasks. The MTTR … Performance(actual speed vs standard speed) 3. All sub target performance is discussed, Root Cause Analysis conducted and improvements tracked. This intuitively relates to the availability of the equipment. 1. Given all the engineering and metrics involved, you would expect a similarly crisp, uniform definition of world-class maintenance. Mean time between failure (MTBF) is a maintenance metric that defines the average time that equipment is operating between breakdowns or stoppages. The widely known adage, “You can’t manage what you can’t measure,” is very accurate for asset management. The five pillars of the SMRP Body of Knowledge (BoK) are a roadmap to world-class performance. 10880 Willshire Blvd, Los Angeles, CA 90024, Percentage of work covered by a work order. Each pillar details an area of maintenance, reliability and physical asset management that practitioners and professionals should be proficient in to improve their careers. 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? Unscheduled downtime: This results from unforeseen breakdowns and requires work orders that are not scheduled out in advance. Average days to complete work ordersmay be used to determine whether a maintenance team is becoming more productive. ... –Publish metrics . Facility Maintenance Metrics Mean Time Between Failures (MTBF) The Mean Time Between Failures (MTBF) is the average time between each failure. Some of the variables to iron out before applying is the definition for "uptime". There's much to see here. Or is this more akin to being the one-eyed man in the kingdom of the blind – you're up here only because everyone else is down there? For example is <3% considered world class or <5%, 10%, etc….Thanks. However, the latter is necessary to increase equipment availability in the long term. MTBF (mean time between failure) and MTTR (mean time to repair) Supply Dollar Spend. Invite your whole team. 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. 70% of the companies' lack awareness of which assets require maintenance which leads to unpredictable failures and costly downtime. Common maintenance metrics. Phone: (864) 722-3086 Email: rsmith@worldclassmaintenance.org. Mean time to repair (MTR) is the average time it takes for equipment to be diagnosed, repaired, and recovered after experiencing a failure. Machine Downtime Versus Uptime. By determining which metrics are key measures of success, maintenance operations are … Performance Management: KPIs and process metrics are clearly visible, and understood by all. Number of Minor Stops. My old math teacher used to say he didn't care how well we did against each other but against the right answers. Maintenance overtime is less than … Maintenance backlog is a measure of required maintenance work that has not yet been completed. Planned Maintenance Percentages can be easily tracked with an effective CMMS. 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. The idea is to speed up the equipment’s rate of recovery from failures and breakdowns. Was wondering if there’s any industry benchmark levels once you have a % calculated. Does your company do all it can to consistently enable excellence within your maintenance organization? 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? Your plantwill hav… However, if you do a Google search for "world-class maintenance," you will get approximately 586 million results. Fleet Maintenance Metrics Performance Metrics are a tool we use to examine our function as a fleet management team. World Class Production through World Class Maintenance is a Life Style Change. WHAT IS WORLD-CLASS MAINTENANCE? Downtime is incredibly costly for any company which has assets. A world-class organization has maintenance professionals involved very early in a project. As a basis for comparison with your own process, 10% is a good number for this metric, and a 5% ranking signifies a world-class maintenance effort. OEEis a much talked about KPI and shows how manufacturing assets perform relativeto their theoretical maximum potential. While neither measure is strictly maintenance-oriented, Shiver says maintenance can influence both … World Class Manufacturing gives a company the lowest costs, the fastest time to market, the best customer service and satisfaction, the highest quality, the shortest product lead time, the highest return on investment and the most productive work force. So you want to set up some KPI metrics for your maintenance team. 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. Availability, also known as uptime, is one of the key indicators of overall equipment effectiveness and is always a focus area for improving productivity. The best “simply do the basics very well.”* 2. That’s why the most widely-used maintenance metrics address the way equipment and people work. Some of those metrics include: Number of Breakdowns. Everything in maintenance revolves around humans and machines. Maintenance schedule compliance is greater than 90 percent. World class maintenance backlog: ~2 weeks worth of tasks per technician. By keeping a data-driven mindset and proactively improving the MTR, the manufacturing processes can reduce availability losses due to repairs. Welcome. Instead of placing equal importance on every metric you track, choose a few KPIs. Moving forward in the maintenance excellence path requires having the appropriate dashboard with gauges showing the correct measures. What is Estimated Plant Replacement Value a? Businesses that invest heavily in plantwill find that OEE measurement is an essential metric to track. Do you have a world-class maintenance mindset? However you are presented with literally hundreds of options. (Uptime is often synonymous with availability. We are just starting to look at using this type of metric at our plant and this info was very informative. Schedule compliance is a maintenance metric that measures the percentage of time that scheduled work orders are completed. 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). Very few factories in the world are operating at these efficiency levels, hence is why it's regarded as World-Class. What is Availability as a Maintenance Metric? You can also choose a few “leading indicators” that help you determine why KPIs are getting hit or being missed. 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. Equipment availability is at least 90 percent. Tracking, analyzing and optimizing the performance of these two elements is the key to maintenance success. Clemson, South Carolina 29631, United States. Availability(actual running time vs running time) 2. These metrics signal if the athlete has beaten the previous records, elevating him or her to "world class." 09:00 am – 05:00 pm. Too much backlog, on the other hand, can lead to a surplus of deferred maintenance which is not good. These professionals know how to perform reliability and maintainability analyses of systems and components. 1. Overall equipment effectiveness (OEE) is a standard used for measuring plant performance. Each minute a critical asset is unavailable, especially in … 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: Some say world-class maintenance means being in the top 5 percent of certain metrics. Open today. See your entire space at a glance and optimize maintenance planning. The truth is, if you want some easy to understand, easy to analyse maintenance KPI’s there are only 3 that you really need. Trigger maintenance tasks based on equipment use. Organizations that are committed to measuring the effectiveness of their scheduled maintenance process use schedule compliance as a performance metric. We hope you enjoy our site and take a moment to drop us a line. Optimizing the performance of people and assets is crucial to maintenance success. World class schedule compliance: 90% or greater. Having a good Maintenance Strategy in place, can reduce downtime by more than 30%! An 80% planned to 20% unplanned ratio is considered still beneficial, compared to the typical average of 55% or less. Common maintenance metrics. However, as shown in Figure 4, North America is at 65.9% Actual Proactive Maintenance while Global is at 72.4%. 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