By Bryan Christiansen, Limble CMMS.
Source: maintworld.com
Effective maintenance of equipment is a critical factor in
delivering quality operations that provide timely resources at a minimal cost.
However, those in the maintenance field understand that equipment reliability
does not come easy.
Organizations need to set quality benchmarks to measure the
current effectiveness and predict future performance and use the data obtained
to understand where to make improvements.
One way to do this is by using different maintenance metrics
to understand the equipment performance. These metrics are very important as
they can mean the difference between achieving the overall business goals and
explaining how unexpected breakdowns caused yet another production delay.
What are the maintenance metrics?
There are two categories of maintenance key performance
indicators which include the leading and lagging indicators. The leading
indicators signal future events and the lagging indicators follow the past
events.
The leading indicator comprises metrics like the
Estimated vs actual performance and PM Compliance, while the lagging indicator is reflected in maintenance metrics like the Mean Time To Repair
(MTTR), Overall Equipment Effectiveness OEE and Mean time between failure
(MTBF).
Using these maintenance metrics and turning the data into
actionable information, organizations can acquire both qualitative and
quantitative insights.
And there is no better way to spot opportunities for
improvement.
Here are some important maintenance metrics you should track
if you want to improve and optimize your maintenance operations.
1. Planned maintenance percentage (PPC)
This metric represents the percentage of time spent on
planned maintenance activities against the unplanned.
In simpler terms, this metric tells you how much maintenance
work done on a particular asset was a part of your preventive
maintenance plan versus how much time you’ve spent repairing it because it
unexpectedly broke down.
In a great system, 90% of the maintenance should be
planned.
The calculation is as follows:
PPC= (scheduled maintenance time/total maintenance hours) x
100
2. Overall Equipment Effectiveness (OEE)
OEE is the measure of the productivity of a piece of equipment. It gives
informed data on how effective an organization’s maintenance processes are running
based on factors like equipment quality, performance, and availability.
A 100% OEE means that your system is producing no defects,
as fast as possible, and with no stops in the production.
understanding OEE and the underlying losses,
organizations can gain significant insights into how to improve their
manufacturing processes. Using this metric, you can identify what has a
negative impact on your production, so you can eliminate it.
To calculate the OEE, you multiply the availability by
the performance and quality :
OEE = availability x performance x quality
3. Mean time to repair (MTTR)
MTTR is the measure of the repairable items'
maintainability.
The MTTR clock starts ticking when the repairs start and it
goes on until operations are restored. This includes repair
time, testing period, and return to the normal operating condition.
The goal of every organization is to reduce MTTR as much as
possible. This is especially important for critical assets as every additional
hour you need to restore an asset to a working condition amount to huge losses
for your firm.
To calculate MTTR, you divide the downtime period by the
total number of downtimes:
MTTR= (SUM of downtime periods/ total number of repairs)
4. Mean time between failure (MTBF)
MTBF is the measure of the predicted time between one
breakdown to the next during normal operation.
In essence, MTBF tells you the expected lifetime for a
specific piece of equipment. Higher MTBF means that the part (or product) you
bought will work longer before it experiences failure.
If you know how long a specific part/equipment will last, it
gets much easier to predict and prepare for a failure or schedule some preventive
work.
To calculate the MTBF, you divide the total operational time
by the number of failures:
MTBF= (SUM of operational time/total number of failures)
5. Preventive maintenance compliance (PMC)
PM compliance is defined as the percentage of the preventive
work scheduled and completed in a set time.
For example, you might have 60 Work Orders (that are a part
of the PM plan) scheduled but 51 completed at the end of the month.
In this case:
PMC= (51/60) x 100 = 85%
This tells you that 85% of all preventive WO’s have been
covered for selected month.
The disadvantage of this metric is that it doesn’t tell you
if the WO’s have been completed on time.
That is why you need to invest some additional effort and
also track if the Work Orders are actually being finished on time.
By far the best way to do that is to use a CMMS as it allows
you to quickly create, assign, and track all of your WO’s from one place.
Conclusion
The best way to track if your actions have a positive impact
on your maintenance operations is to accurately track metrics that can show you
if you are going in the right direction.
Improvements based on your “feeling” can never be as good as
relying on hard data.
Bryan Christiansen is the founder and CEO of Limble CMMS.
Limble is a modern, easy-to-use mobile CMMS software that takes the
stress and chaos out of maintenance by helping managers organize, automate, and
streamline their maintenance operations.
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