Correctly Measuring KPI’s and Metrics is crucial to the success of your department and the entire organisation. Setting a high-quality benchmark gives a clear picture of where you are at and allows you to make improvements and measure the effectiveness of change going forward.
6 of the most important maintenance metrics for success are outlined below. This will help you cut through the clutter and identify the key metrics your organisation needs to measure in order to develop a world class maintenance facility.
Key Maintenance Metrics:
- Mean Time to Repair (MTTR)
- Mean Time Between Failure (MTBF)
- PM Completion
- Planned Vs Unplanned Maintenance
- Root Cause
- Maintenance Backlog
Mean Time to Repair (MTTR)
Simply put, this is the average time required to restore failed equipment to working order and a return to production. With this method, you will have knowledge and evidence of how your organisation responds to planned repairs, unplanned equipment problems, how long production is interrupted and the average repair time of each specific component.
Mean Time Between Failure (MTBF)
This is the average time between equipment failures. This KPI needs to be measured for each piece of critical equipment and is the most efficient way of analysing the reliability of an asset and predicting future performance. This is vital when scheduling preventative maintenance to reduce downtime and ensures you do not over maintain your assets.
Performing preventative maintenance on functioning equipment to reduce the likelihood of failure is an effective way of reducing asset downtime and increasing the lifespan. It’s also important to track if scheduled work is carried out and if it was on time. This needs to be measured in order to properly assess the effectiveness of your preventative maintenance program. If you have a strategy and don’t adhere to it, failures and disruption to production can be expected.
Planned Vs Unplanned Maintenance
This will help to determine maintenance maturity in your organisation. Above 90% planned is considered world class. Over 70% planned is considered to be acceptable with room for improvement. If you are below this it may be problematic for your organisation. This KPI will allow you to clearly evaluate the effectiveness of your preventative maintenance program and monitor improvements over time.
It’s important that you don’t just resolve an issue and move on. A deeper understanding of recurring problems can help your maintenance department move forward. If it’s human error, more training may be needed. Over using assets, quality of spares and technician skills can all have a detrimental long term effect on your maintenance department and need to be identified with remedial actions put in place.
A very common problem even when you try to avoid it. This needs to be tracked as the longer it is left the more likely you are to have compliance issues or asset breakdowns. Visibility is key here. Know what work orders are overdue and prioritise them.
Data is key to making informed decisions. Each facility will have its own set of KPI’s used to measure performance. By adopting the above 6 maintenance metrics it will give insights into your machinery, maintenance strategy and personnel and allow you to make positive changes, track and measure them over time.
Remove all guesswork and assumptions from your factory floor, reduce operational risk and add value to your organisation’s bottom line.
Reducing cost, downtime and failures is possible if you correctly implement, track and measure these maintenance metrics. A good CMMS can contribute to effective business operations and manage and measure these KPI’s. A correct approach to CMMS implementation will set your facility and organisation up for long-term success.
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