Calculating MTTR & MTBF with Zero Failure Metrics

Important metrics that the industrial sector should be aware of. An important strategy for achieving production goals is to track reliability metrics, or metrics that measure the reliability of a system or machine. Two important reliability metrics are Mean Time Between Failures (MTBF) and Mean Time to Recovery (MTTR or MTR).

Calculating MTTR & MTBF with Zero Failure Metrics

This article details the meaning of these indicators, how to calculate them, and how to make them an effective part of your company's Asset Management strategy. But first, let's discuss why these metrics are critical to your business.

The Importance of Reliability Metrics

According to industry experts, keeping equipment running until a failure occurs can cost up to 10 times more than a preventive maintenance program; This is why reliability metrics are so important. They provide important insights into equipment conditions, extend the time between machine failures, and help predict downtime for equipment or services.‍

If downtime is more predictable, time and money budgets can be budgeted, projected production goals can be made more realistic, and machine replacement costs can be completely avoided over the next few years.

Next, let's examine the difference between the two metrics.‍

What Is MTBF?

Mean Time Between Failures (MTBF) measures the mean time between repaired failures of a product, excluding planned downtime. This measurement gives enterprises valuable insights into product reliability.

For example, an operations manager at a steel manufacturing company is wondering whether to replace an industrial electric arc furnace; This is a costly investment in the company's production process, but it is a necessary investment. After reviewing MTBF statistics (and other reliability metrics), the manager found that the machine was more reliable than originally thought and could be improved by replacing specific parts rather than the entire machine; This saves companies thousands of dollars and loses production time while improving the capabilities of existing machines.‍

How to Calculate MTBF?

MTBF = Total Number of operational hours in a period / Number of failures that occurred in that period

It is important to note that MTBF does not consider the time it takes to fix a problem, only the time between failures.‍

The MTBF is very useful because manufacturers can use this metric to plan the production of their products. Although the exact failure cannot be completely predicted, the frequency and need for planned maintenance are as follows:‍

How to Improve MTBF?

Of course, the MTBF of gears is not always high. Machines are aging, parts are out of order, and engineers come and go. If you are not satisfied with the component's MTBF, you can take steps to improve it. Let's discuss ways to increase the time between unplanned outages or increase MTBF.‍

Use trained and qualified staff and follow best practices
Make sure your staff is qualified and experienced. We also provide device-specific training appropriate for new employees and new products. Proper use of the product is important to reduce failures.
Use high-quality replacement parts
Cheap replacement parts often lead to cheap repairs. Use high-quality recommended replacement parts to extend the failure interval and maintain the machine's overall condition.‍
Follow regular maintenance recommendations
Keeping regular maintenance up-to-date can reduce unexpected downtime. Regular maintenance is ideal because it can be scheduled and incorporated into scheduled downtime.‍

What is MTTR?

MTTR has multiple meanings, but it is usually the average time it takes to repair a system after an unplanned outage.‍

The MTTR includes the entire repair process. It starts with the start of the repair and ends with its testing and fully functional components.‍

Imagine an injection molding company installing a new thermal heater. MTTR is unusually high and will take a very long time to repair. Since the machine is new, the administrator cannot understand why. After a bit of digging, they realized that their technicians weren't used to this new model. Providing proper training to technicians can quickly reduce MTTR. With MTTR, managers were able to fix problems while keeping production going quickly.‍

How to Calculate MTTR?

You can calculate MTTR by dividing the total maintenance time by the total number of maintenance actions over a period of time.

MTTR = total maintenance time / total number of maintenance actions‍

Because MTTR is designed to provide mean time to repair, onsite results may vary depending on factors such as severity, availability of parts, and qualified repair personnel. However, MTTR can help indicate a problem. B. When replacing components, conducting further staff training, or updating SOPs.‍

How to Reduce MTTR?

The goal is always a low MTTR, as repair times are reduced. The higher the MTTR, the longer the downtime, which affects the availability of components and the production of goods or services. A high MTTR can have a negative impact on your business.‍

Here are Some Best Practices to Help Reduce MTTR

Proper training
Ensure all repair personnel are properly trained for each particular type of equipment. Proper training can improve the efficiency of repairs.
Repair process optimization
Is the repair process as wasteful as possible? Remove or make changes to unnecessary steps to make the process comprehensive and as efficient as possible. Checklists are also useful when optimizing the repair process.
Machine Performance Tracking
Machine performance tracking can speed up the evaluation phase of the repair process, as the analyzed data points out specific issues and helps staff allocate resources for future repairs.
Streamline maintenance deployments with tools
Maintenance and reliability applications can help streamline processes and provide a command center for maintenance management.

What is the Difference Between MTBF vs. MTTR?

MTBF and MTTR are often closely related but have very different reliability indicators.‍

The mean time between failures calculates the average time a device will operate without unplanned outages. For example, a manufacturing company's industrial HVAC machine runs on demand for 40 consecutive days over three months, with three unplanned downtimes; This is the information needed to calculate the MTBF.‍

On the other hand, the mean time to repair determines the average time required to repair a device. Suppose a chemical company technician takes an average of 34.7 minutes to repair a packaging machine in the event of a breakdown; This is MTTR.‍

Although the MTBF and MTTR have different uses, these two calculations are important for predicting future equipment downtime and improving overall reliability.‍

Managing MTBF and MTTR

Reliability metrics help ensure the availability and productivity of the components essential to your business growth. Cryotos is an essential tool for managing and even improving these indicators.‍

Cryotos is an easy-to-use mobile-first maintenance and reliable application designed to improve technician utilization and efficiency in processing work orders. The platform includes a central command center that allows technicians to manage and share the required information about work orders in one place. Users can also create custom dashboards and reports to track key maintenance data that helps improve reliability.‍

Cryotos also provides real-time monitoring using IoT sensors. This IoT data can play an important role in improving reliability. If that's not enough, Cryotos has a variety of preventive maintenance checklists to help you start or improve your preventive maintenance program and ultimately reduce equipment downtime. Get a free Cryotos Maintenance Software product tour now!

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What Do Our Clients Says ?

Amrapali Exports - Esteemed Clients of cryotos
Anuraj Sharma - Maintenance Manager

The best thing about Cryotos CMMS software is that it always tells me when something needs to be fixed - before it breaks and cost me a fortune!

The software is very user-friendly, and even if I don't know how to do something, the support team is always there to help me out.

Most importantly, unlike other such software, Cryotos is editable and hence the user can modify how the software works as per their need, we made several changes in the workflow & flowchart with the help of development team.

I don't know what I would do without Cryotos! I've been using it for years, and it has saved me so much time and money. I highly recommend it to anyone who wants to manage their assets efficiently.

Resil Chemicals - Esteemed Clients of Cryotos
Jeevan Belliappa - Head, Information Technology

Since we've been using Cryotos CMMS Software, our asset maintenance management has been running more smoothly than ever. We're able to track and optimize our preventive maintenance with ease, thanks to the customized process workflow. This has been a lifesaver for our team!

The Cryotos CMMS software has allowed us to manage our assets more effectively and efficiently. It has helped us to improve our asset utilization. The software is user-friendly and easy to navigate, and the support team is always quick to help with any questions we have. We're very happy with the results we've seen so far and we're confident that we'll continue to see improvements in our asset management as we use the Cryotos CMMS software.

Planys - Cryotos Esteemed Client
Antony Jacob Ashish - Lead, R&D

Cryotos goes above and beyond when it comes to customer satisfaction. Planys Technologies use Cryotos for preventive/ corrective maintenance of our critical systems and not once did we face a problem that was not dealt with immediately. The team is extremely professional and helpful. We can rely on Cryotos when it comes to the operations and processes.

Thanks to the whole team for the amazing performance and thought leadership. It's rare to see teams that can put themselves in the customer's shoes and think from their perspectives - Cryotos team doesthat and more.

We recommend Cryotos if you are looking to put an end to your preventive maintenance problems and sign up with them!

Thanks to the team for an awesome job.

Xpert IFM - Esteemed Clients of Cryotos
Siva Shankar - AGM, (Operations & BD)

On behalf of Xpert FMS we would like to express our sincere appreciation for the excellent support Cryotos team have provided us for our building and facility management. Cryotos has always provided support that is timely and meets our expectations. Professionalism and quick response are the hallmarks of this team.

Sincere appreciation for the team's brilliant performance and wish them continued success. We highly recommend Cryotos as they have executed well on all assigned tasks and continue to outperform.

Thanks to all the hard work, our lives have become easier.

ST Jude India Childcare Centers - Cryotos Esteemed Client
Mukesh J - CIO

We are able to raised the workorder and tracking of these till the closure as helped us to provide better services our beneficiaries. Workflow-based work order management has helped us to define processes for each locations separatley. System provide notification once order is raised for assignment to engineer.

Maspro - Esteemed Clients of Cryotos

This CMMS software is top-notch! I can't believe how much it has helped me with my facilities maintenance management. Customized reports and business intelligence have been invaluable in making better decisions.

The software offers a great deal of customization for each organization's specific needs. They are always updating the software with new features and improvements, which is great. The support team is fantastic - they are always quick to help with any questions or problems we have. This software has definitely made my life a lot easier! It's so easy to use and it's really helped me keep track of all my maintenance tasks in one place. I would definitely recommend it to anyone looking for a CMMS platform.

Al Zain Farms LLC - Esteemed Clients of Cryotos
Mr. Vishnu S Nair

Since we've started using Cryotos, our team has been able to stay on top of all the various SOPs. Checklists and safety procedures are now easily accessible to everyone, and we can quickly reference them whenever we need to. The software has definitely helped to improve our team's communication and efficiency. Plus, the fact that it's cloud-based means we can access it from anywhere, which is a big plus. It has been a great help in keeping everyone on the same page and up to date with the latest procedures.

Dinex - Esteemed Clients of Cryotos
B S Vijaya K. - Maintenance Engineer

At starting it felt some what difficult for scheduling but now it made to easy access.

Review from Capterra

Korrun - Esteemed Clients of Cryotos
Nithin G. - Maintenance Incharge

Overall: Nice Software
Pros: Scheduling, work order creation, asset inventory, records.
Reasons for Choosing Cryotos: Compared to other products it's easy to use and easy to understand the feature.

Review from Capterra

Aptiv8 IT Solutions
Hashim - Business Project Manager

This CMMS software is top-notch! I can't believe how much it has helped me with my facilities maintenance management. Customized reports and business intelligence have been invaluable in making better decisions.

The software offers a great deal of customization for each organization's specific needs. They are always updating the software with new features and improvements, which is great. The support team is fantastic - they are always quick to help with any questions or problems we have. This software has definitely made my life a lot easier! It's so easy to use and it's really helped me keep track of all my maintenance tasks in one place. I would definitely recommend it to anyone looking for a CMMS platform.

Gurit - Esteemed Clients of Cryotos
Mr. Mohanmurali R

I recently purchased Cryotos CMMS Software for asset management needs at my organization and after a few months of testing and monitoring, I'm incredibly pleased with the results. The software is user friendly, accessible and the design is very intuitive. It covers all the aspects of managing maintenance and repair, starting from preventive maintenance and standardizing operation cycles, to scheduling and streamlining workflows. I am highly satisfied with the performance and the range of features offered by Cryotos. Highly recommendable!

Metro Tyres - Esteemed Clients of Cryotos
Mr. Sanjay Beri

Before using Cryotos, asset management and maintenance seemed like an uphill task for my team. Manual processes laden with human errors did not work for us at all. We decided to go with Cryotos after checking out similar products in the market.

The user interface of the software is intuitive and easy to use, making it simple to navigate through the different features and functionalities. I particularly appreciate the ability to track all assets in real-time, allowing me to keep a close eye on their performance and maintenance needs.

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I highly recommend Cryotos to anyone who would like to unburden themselves of maintaining and managing their critical assets.

Dinex - Esteemed Clients of Cryotos
Mr. Yuksel Aksin

As a customer of Cryotos CMMS software for asset management needs, I must say that I am thoroughly impressed with the features and functionality offered by the platform. Cryotos CMMS software has made managing my assets a breeze, and I no longer have to worry about missing maintenance or inspections.

One of the standout features of Cryotos CMMS software is the ability to generate work orders and schedule maintenance tasks. This has made it easy for me to stay on top of maintenance and repair tasks, ensuring that my assets are always in optimal condition.

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