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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
