Measuring Equipment Performance Using Maintenance KPIs and Metrics

Measuring Equipment Performance Using Maintenance KPIs and Metrics

Understanding the performance of your maintenance processes is a critical component of facility management. Key Performance Indicators (KPIs) and metrics offer valuable insights into the efficiency of your operations, helping you make data-driven decisions and optimize your maintenance strategy. In this post, we'll dive into the essential KPIs and metrics you need to keep your finger on the pulse of your maintenance performance.

Mean Time to Repair (MTTR)
This is one of the most crucial metrics in maintenance management. It measures the average time taken to repair an asset after a failure. A lower MTTR indicates a more efficient maintenance team and less equipment downtime.
Formula: MTTR = Total Downtime / Number of Repairs
Mean Time Between Failures (MTBF)
MTBF indicates the average time between asset failures. A higher MTBF suggests greater reliability of your assets.
Formula: MTBF = Total Operational Time / Number of Breakdowns
Overall Equipment Effectiveness (OEE)
This comprehensive metric overviews asset performance, considering availability, performance, and quality. High OEE scores denote optimal use of assets.
Formula: OEE = Availability x Performance x Quality
Preventive Maintenance Compliance (PMC)
This KPI reveals how effectively your team follows the preventive maintenance schedule. A higher percentage signifies greater adherence to the planned maintenance, which helps avoid sudden breakdowns.
Formula: PMC = (Number of Completed Preventive Maintenance / Total Scheduled Preventive Maintenance) x 100
Downtime
This metric tracks the total time your assets are non-operational due to failures. Minimizing downtime is a significant part of enhancing productivity and efficiency.
Formula: Downtime = MTTR x Number of Breakdowns

Monitoring these metrics becomes simpler and more accurate with a robust Computerized Maintenance Management System (CMMS) like Cryotos. By offering real-time data tracking and analytics, Cryotos enables you to keep tabs on your maintenance performance effortlessly. It also supports proactive preventive and predictive maintenance strategies, thereby reducing MTTR and improving MTBF and OEE.

The importance of measuring these maintenance metrics cannot be overstated. They not only highlight inefficiencies but also provide a roadmap for improvements. Incorporating these KPIs into your maintenance management routine is the key to unlocking unprecedented asset reliability and performance. Remember, you can't improve what you don't measure.

Here's a sample record based on hypothetical data for a year:

Month Total Downtime (Hours) Number of Repairs Total Operational Time (Hours) Number of Breakdowns Completed Preventive Maintenance Scheduled Preventive Maintenance
Jan 25 5 700 5 15 20
Feb 20 4 670 4 18 20
Mar 15 3 720 3 20 20
... ... ... ... ... ... ...
Dec 30 6 650 6 16 20

Calculations for Maintenance KPIs

MTTR = Total Downtime / Number of Repairs
For January, MTTR = 25/5 = 5 hours
MTBF = Total Operational Time / Number of Breakdowns
For January, MTBF = 700/5 = 140 hours
Preventive Maintenance Compliance (PMC)
PMC = (Number of Completed Preventive Maintenance / Total Scheduled Preventive Maintenance) x 100
For January, PMC = (15/20) x 100 = 75%
Downtime
Downtime = MTTR x Number of Breakdowns
For January, Downtime = 5 x 5 = 25 hours (which is the provided total downtime)

These calculations can be carried out monthly to understand the trends in the metrics over the year. This data-driven approach would help identify potential improvement areas and make informed decisions for enhancing the maintenance operations.

Please note that the calculation for Overall Equipment Effectiveness (OEE) isn't included here as it requires additional information on asset performance and quality, which isn't provided in the table.

Best Practices

Prioritize Metrics
Not all metrics are created equal. Some KPIs will provide more insight into your specific operations than others. Prioritize and focus on the metrics that are most meaningful for your business.
Regular Reviews
Schedule regular reviews of your KPIs to see how you're doing; This could be monthly, quarterly, or annually, depending on your needs.
Set Realistic Goals
Don't aim for perfection - aim for improvement. Recognize that certain factors will always lead to downtime or repair, and set your goals accordingly.
Leverage Technology
Use modern tools like CMMS (Computerized Maintenance Management System) software to automate tracking and reporting on your chosen KPIs.

Use Cases

Improving Efficiency
A major university's transportation department wanted to improve its bus fleet's efficiency. By tracking MTTR and MTBF, they identified a recurring issue with certain bus models and worked with the manufacturer to solve the problem.
Reducing Costs
A food manufacturing plant was experiencing higher than normal maintenance costs. Using their CMMS to track maintenance costs and downtime, they discovered that much of the work was reactive, not preventive. By changing their maintenance strategy, they were able to reduce costs significantly.

Benefits

Increased Uptime
Tracking metrics such as MTTR, MTBF, and downtime can help your organization understand inefficiencies and address them to increase uptime.
Better Decision Making
Understanding your performance through these metrics gives you the data to make informed decisions.
Reduced Costs
By identifying inefficiencies and taking steps to improve them, you can reduce both your maintenance costs and the costs associated with downtime.
Improved Safety
Regular maintenance and reduced equipment failure can lead to a safer work environment.

Remember, effective tracking and management of maintenance KPIs and metrics can substantially improve productivity, cost savings, and operational efficiency.

References

Important Maintenance KPIs To Monitor, Track and Improve Team Performance

5 Important Maintenance Metrics and How To Use Them

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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
Mr.Robert

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.

Customized work order and workflow creation has reduced the needs to always follow a particular template. Depending on our needs we can create tailor made workflows to suit our requirements.

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.

The software also allows me to track inventory levels which has streamlined my inventory management process. The ability to generate reports and analyze asset performance data has also been invaluable in helping me make data-driven decisions about my assets. Overall, I would highly recommend Cryotos CMMS software to anyone looking for a reliable and efficient asset management solution.

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