It enables management to compare alternate methods and also to do initial staffing. Assuming that you intend to run your business based on the story that the metrics tell, a concerted effort must be made to ensure that you are receiving a true picture from the field. Overall Equipment Effectiveness (OEE) OEE is the measure of the productivity of a piece of … Learn the most important maintenance KPIs to help you achieve a world-class maintenance management system. For example, your organization’s ultimate goal might be to cut costs by a certain amount. International Labour Organization (ILO) defined work measurement as ‘die application of techniques designed to establish the work content of a specified task by determining the time required for carrying it out at a defined standard of performance by a qualified worker’. Suppose there are 300 man-hours of PMs in the weekly schedule, and that 230 hours of these are done on time. Work measurement Part II of Work Study Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Although every facility will have different targets, some of the most common maintenance KPIs revolve around a few key elements, including: Maintenance metrics are measurements that give you insight into how everything and everyone is operating at your facility. Illustrations in maintenance cases are outlined. My question is - deos SAP have a process to automatically issue a Work order, based on that warning. This tells you how many days on average it takes to … There are four major reasons why "work measurement" is wrong: 1.) Eight questions shaping the future of maintenance. If the weekly maintenance schedule had 100 separate work orders (planned jobs) on it, but there were three breakdowns (emergency jobs) that took 89 man-hours to repair, the metric would become 3 emergency jobs / 100 planned jobs × 100 = 3%. It does not consider if people are busy doing the right thing. Now, suppose that out of your 400 available man-hours, 89 of them were spent on emergency breakdowns. That’s why you must take great care to choose the right maintenance metrics to measure before beginning to track the data. The most successful organizations track several KPIs. a growing trend in work resulting from inspections would show that your preventive maintenance (PM) program is being more effective (or your equipment is quickly deteriorating). Maintenance KPIs vs. maintenance metrics: What’s the difference? Another way to state this sobering statistic is to say that 23% of your bearings are running hot due to too little grease because the PM was late, or that they are running hot due to too much grease because the PM was performed early. This extremely important metric — also called Emergency Work — is a measure of how much unplanned emergency work your maintenance department does. If you use printed work orders, you should have a time-stamp system. As such, it is actually a very good measure of how far out of control your particular process has drifted. This question helps you close the loop. They quantify the daily activity of maintenance, and in doing so, paint a picture of how people and assets are working. An Emergency Work percentage of only 3% would imply that your maintenance department ranked among the best in the world, but three breakdowns that consumed 89 man-hours to repair indicates a different reality altogether. Fiix® is a registered trademark of Fiix Inc. What you’re shooting forIn a perfect maintenance world, you might expect Preventive Maintenance man-hours to fall somewhere between 50% and 70% of your maintenance man-hours, and 85% of this critical work would be completed on time. These are your goals, the numbers you are shooting for. In order to illustrate this metric, let us assume once again that we have 10 technicians scheduled at 100% of their 40-hour weeks. It is a measure of … Maintenance KPIs measure how well your operation is doing at achieving its maintenance goals, like reducing downtime or cutting costs. World class unscheduled downtime: 10% or less Equipment availability: This is a measure of how often a piece of equipment is available for … Lack of Full Support If a work measurement system is to be implemented and used effectively, it must be supported by everyone involved: the employees doing the work, management, those using the information, and those conducting the study. Maintenance overtime would be figured as Overtime Hours (78) / Total Hours (478) × 100 = 16%. Whatever you call it — metrics, measurements, or key performance indicators (KPI) — maintenance and engineering managers must have performance measurements in place either to validate that the work their staffs are performing in achieving the departments’ goals and objectives or to identify opportunities for continuous improvement. Analyze your data, find trends, and act on them fast, Explore the tools that can supercharge your CMMS, For optimizing maintenance with advanced data and security, For high-powered work, inventory, and report management, For planning and tracking maintenance with confidence, Learn how Fiix helps you maximize the value of your CMMS, Your one-stop hub to get help, give help, and spark new ideas, Get best practices, helpful videos, and training tools. If that message looks like a string of nonsense, it won’t do your operation much good. There are three main categories of maintenance metrics — asset, operational, and inventory metrics. The computation of the metric is Scheduled Man-hours Completed (400-89) / Scheduled Man-hours (400) × 100 = 78% Planned and Scheduled Work. Incidentally, the reason that this metric should be defined in terms of man-hours rather than jobs has to do with the indefinable nature of the concept “job.” Take the preceding example. As a basis for comparison with your own process, 10% is a good number for this metric, and a 5% ranking signifies a world-class maintenance effort. Deferred Corrective Maintenance. https://www.fiixsoftware.com/important-metrics-maintenance-department But, first things first. 2.) The remaining 5% to 10% will be spent on emergency work. Now that you know what metrics to measure, you need to know how to track them. 1) Work measurement - setting the standard before the job is running 2) Standards database - for standards that have been set, and for maintenance of the standards Responsibilities of Analyst How can you measure progress and influence the outcome? It is a variation of the metric called “planned maintenance percentage” that’s discussed below. Without measurement data, we cannot determine the capacity of facilities or it is not possible to quote delivery dates or costs. Understanding each helps connect the dots between actions and impact, so you can make informed decisions and upgrade your facility. The findings reported are … Forward Snapshot The forward snapshot is taken prior to commencement of the scheduling week. That is, to collect an entire week work of data as one sample. Work orders that are returned in pristine condition may have been completed in the locker room or at the break table. In the chart of maintenance types I broke ‘corrective … Once again, we will assume that emergency breakdowns consumed 89 man-hours out of the work schedule. In other words, maintenance KPIs are a target your business is aiming at and maintenance metrics are the arrows you’re shooting at that target. Select metrics that are relevant to your organization’s goals, can be understood by you and your team, and can be used to make a difference in the way you work. Suppose you have 10 technicians in your organization, each of whom works a 40-hour week with 100% of their time scheduled. This metric, also known as PMs Completed on Time, is no less than the meat and potatoes of your maintenance effort. A world-class maintenance organization will spend 70% of its man-hours on preventive maintenance activities, and the successful execution of the PM program is the difference between success and failure. The Green Edge: DuPont Collaboration To Boost Solar... Communications: Improving Maintenance Work-Request... Work orders can be handed out by the day, but should be retrieved by the job. It also means that 23% of your visual inspections were not performed in a timely manner, so perhaps one out of your last four breakdowns could have been prevented if these inspections had been performed on time. It should be noted that for many maintenance organizations a 16% overtime rate would be considered real progress. Either way, you need to understand what the finish line looks like and what to do once you’ve crossed it or not. That’s where this next preventive maintenance effectiveness metric comes in. You can’t use either of them unless you have the right infrastructure, like equipment, staff, delivery trucks, and more. A number of examples are provided to demonstrate the concepts. Maintenance KPIs and maintenance metrics are often used interchangeably. Everything in maintenance revolves around humans and machines. Copyright © 2021. In the foregoing example, this would be 100% – 22% = 78%. Also known as Maintenance Overtime, this simple metric is a fair measure of the health of your maintenance organization. Still, it is a truism — because it is true — that maintenance technicians, as a group, are notoriously poor at paperwork, and you need good data with which to run your business. All Rights Reserved, NEC 2020 Enhances Service Entrance Safety, SPONSORED: Three Ways to Increase Efficiency in the New Year, A Calibration Service May Be Your Solution, Augmented Reality Delivers Maintenance Offering for Italian OEM, Provide Career Paths For Multiple Locations, Apache PowerCleat Belting from Motion Industries, Pump Upgrades Can Improve Efficiency & Reliability, Turn Downsizing Into Improvement Opportunities. The computation for this metric would be On Time PM hours (230) / Total PM Hours (300) × 100 = 77%. Otherwise, the tendency is to get the paperwork back with times charged to them that are suspiciously similar to the scheduled times. Maintenance Overtime as a Percentage of Maintenance Time. In fact, sometimes “too early” is worse. It does not promote cooperation between management and crafts people. You’ll reach your goal and create a new one, or come up short and make adjustments. Measurement: Example: Number days to complete (lab results, reports, charts, audits) 325 to 380 transactions are completed per week. They are an endpoint you are reaching for. Metrics are like any other raw material at your facility. In other words, you have 400 man-hours scheduled. Connect with maintainers from around the world, Learn more and join The Fiixers community. If it is trending down, it could be an indication that the measures you have put into place are having a positive effect. Blanket work orders written for the purpose of covering unattributed time will not improve your maintenance effort, although they may enhance your metrics. Having a preventive maintenance plan is useless if it’s not followed. Software, like a CMMS, also makes it easier for people to do, measure, and improve their work. Depending on how or if you account for Predictive Maintenance (PdM) hours — many maintenance organizations expense their predictive activities outside of the maintenance budget — these activities should amount to 10% of your maintenance man-hours. There are three key questions you need to ask when setting up a system to track and measure maintenance metrics. The difference between a suc… For example, your ultimate business goal may be increasing revenue by 20%. Before we begin our discussion of maintenance-related metrics, we should give some thought to the topics of scheduled time and work order completion. Also, it is a relatively economical alternative. Also, please note that if you are not scheduling your workforce at 100% of their time, this metric can become skewed. Number or percent so many days old (bills, charges) No more than 2-3 times per year the medical record numbers are still missing after 48 hours. The shortest definition of a maintenance KPI is that it’s a measurement of the performance of particular tasks, systems, teams, or individuals. When you attach numbers to these components, they become KPIs. But there are a lot of different, smaller actions join together to push the boulder, little by little, like inventory accuracy and failure rates. It includes knowing what numbers to look at, your goals, the tools you’re going to use, who is responsible for tracking progress, how you’re going to ensure data is clean, and how often data is tracked and analyzed. strategies, Slow-moving parts percentage and obsolete parts percentage. When it comes to PMs, “on time” is all that counts. Join over 14,000 maintenance professionals who get monthly CMMS tips, industry news, and updates. Along those lines, here are a few suggestions that will improve the quality of the feedback you receive. Maintenance Overtime is calculated as follows: Maintenance Overtime / Total Maintenance Hours Paid. The measurements that you record can go up and down. Planned and Scheduled Work Completion Rate. By placing their trust, in the form of nearly five hundred twenty million dollar appropriation per But, if you record a measurement above 105, or below 95, you get a warning message in SAP. In our previously referenced 10-person maintenance organization, suppose the maintenance payroll hours came in at 478 hours. (I don’t know about you, but many long years ago when I was in school, a 78 was a C, and a C wasn’t an acceptable grade in the Atkins home.). Tracking metrics is not a passive task. Scheduled Preventive Maintenance Hours Completed on Time as a Percentage of Scheduled Preventive Maintenance Hours. And the most effective data uses 2 snapshots: a forward snapshot and a backwards snapshot. The measurement of maintenance performance is often faced with a lack in knowledge about the real function of the maintenance department within organisations, and … You already know how much time you think a job should take. All Rights Reserved, A look at the tools that empower your maintenance team, Manage maintenance from anywhere, at any time, Track, control, and optimize asset performance, Simplify the way you create, complete, and record work, Connect your CMMS and share data across any system, Collect, analyze, and act on maintenance data, Make sure you have the right parts at the right time, AI for maintenance. Also known as Planned and Scheduled Work, this metric is, by definition, the opposite of the metric we just discussed. Do you know how to calculate OEE or MTBF? It can be viewed as a measure of what is going right in your maintenance organization. management. By taking it slow and ensuring you’ve created a solid foundation, your team can harness the power of maintenance metrics and climb to new heights. Metrics are first and foremost a way to communicate — they are meant to convey a message. For example, in the work measurement system, thinking time and trouble-s… Also, it is a relatively economical alternative. Please be sure that your technicians are aware that these procedures are not being required because you don’t trust them, or that you are trying to catch them not doing their work. Many companies only measure maintenance performance with historic indicators. Every metric should relate to specific maintenance KPIs. The right tools capture the numbers and calculate the metrics. There is no substitute for thorough, consistent and correctly performed preventive maintenance activities completed on a timely basis. Preventive maintenance software is one of the best tools for collecting accurate information from every asset, work order, and purchase. Asset capability, operating practices and the maintenance of asset condition all contribute to the ability to meet performance requirements. It also allows you to create processes, like automated reports, that lead to better decision-making. good measure of how far out of control your particular process has drifted Work Measurement is a technique for establishing a Standard Time, which is the required time to perform a given task, based on time measurements of the work content of the prescribed method, with due consideration for fatigue and for personal and unavoidable delays. This month, we’ll focus on a set of metrics that address performance levels in the maintenance organization: Planned and Scheduled Work Completion Rate, Maintenance Overtime, Preventive Maintenance Hours as a Percentage of Total Work and Emergency Repairs as a Percentage of Scheduled Hours. A maintenance performance KPI that appears in a monthly report delivered mid-month is already six weeks out of date for the first week. One of the keys to effective preventive maintenance activities, however, is that they be performed at the proper interval — with too early being as bad as too late. Metrics tell you a lot about how everyday tasks influence the bigger picture, which gives you control over your maintenance operation and practical ways to improve work. For example, the ultimate goal of your maintenance department might be to decrease inventory costs. When companies set attainable maintenance KPIs, they can increase your production, reduce costs, improve safety, and … As discussed in Parts I and II of this series, the real key in beginning to manage by metrics is the collection of meaningful and pertinent data. Furthermore, if the quality of the work order’s execution suggests that additional effort is required, the supervisor receiving the document can point out the information shortfall to the technician on a timely basis. This question helps you take action. There are several ways maintenance can impact this goal, like departmental spending or production waste. However, there’s a difference between the two. Number or percent answered within so many days You can set up a measuring point with a high limit of 105 and a low limit of 95. Thus, we have 400 scheduled man-hours. The paperwork should reflect this. The purpose of this chapter is to present techniques for developing jobs time standards. PMs Completed on Time is a simple metric to calculate. As is the case with any metric, the final result can only be as good as the quality of the input. Optimizing the performance of people and assets is crucial to maintenance success. There are three ingredients for measuring maintenance metrics: Tools, processes, and people. The amount of backlog is expressed as work weeks using the number of man hours of work available and comparing it to the weekly capacity of the maintenance department. Working measurement is analyzed here and a justified initiative guideline is proposed for helping choosing convenient time measurement methods according to each or cumulative job -situations. More about this metric can be found here. KPIs are numbers that tie organizational progress to maintenance performance, while metrics connect maintenance performance to maintenance actions. If you continue browsing the site, you agree to the use of cookies on this website. If your organization uses a printed work order system, beware of work orders that are not greasy, crumpled or scribbled upon. All sorts of quantifiable actions can influence downtime, such as the mean time to repair (MTTR) or planned maintenance percentage. That’s why the most widely-used maintenance metrics address the way equipment and people work. Preventive Maintenance Compliance (PMC) is a measure of how many scheduled preventive maintenance work orders are completed within a set amount of time. their professional judgment to their daily work. MT, Contributing editor Ray Atkins, CPMM, CMRP, is based in Rome, GA. E-mail raymondlatkins@aol.com; Website: www.raymondlatkins.com, © 2020 Efficient Plant. Finally, the right people help your organization run the tools, execute processes, and implement strategies. This might be as simple as saying you’ll reduce maintenance spending by 10%, or committing to reducing production waste by 20%. This metric should trend downward over time. One of the most important measurements of total productive maintenance is overall equipment effectiveness (OEE). You need to establish every way a metric can be influenced, identify the areas you have control of, and build a plan for making a positive difference in these areas. Get help, give help, and spark new ideas together. Who is responsible for the business outcome. Unscheduled downtime: This results from unforeseen breakdowns and requires work orders that are not scheduled out in advance. If Maintenance Overtime is trending up, it may be a sign that part of your process is slipping out of control. The prime objective of good maintenance planning and scheduling is to allow maintenance personnel to prepare and perform the required task in a safe and cost effective manner without encountering time wasting delays.Here are five tips that can make you a more effective Planner/Scheduler. Coming upIn the next installment of this series, we will discuss benchmarks in depth and look at what many consider to be the Gold Standard of metrics — Total Effective Equipment Productivity (TEEP). If a manufacturing level indicator is used to measure maintenance performance, improved maintenance may not result in a proportional improvement in the manufacturing metric. maintenance function. Intuitively, most everyone understands that there is value in maintaining assets in a reliable working state. “Analytical Estimating is a work Measurement technique being a development of estimating where by the time required to carry out elements of a job at a defined level of performance is estimated partly from knowledge and practical experience of the elements concerned and partly from synthetic data.” Having the numbers makes it easier to find strengths, weaknesses, and opportunities for improvement. These numbers also allow you to compare the impact of these actions on the ultimate goals of your department. From a driver regularly changing the oil in his car to the hydraulic technician ensuring the system pressure is consistent on a 3,500-ton metal-forming press, there are innumerable tasks being performed worldwide that keep plant operations going and assets performing. Walk before you run: Harnessing the power of maintenance metrics, Back to maintenance It is based on a principle that an experienced worker can estimate a range of time during which certain task can be completed most of the time. These are your maintenance metrics. As was the case with Emergency Work, this measure should also be made in terms of man-hours. If anything, these documents can have the effect of hampering your improvement initiatives by making your current maintenance reality seem rosier than it actually is. This instruction provides guidance, procedures, and responsibilities for the AFMC Depot maintenance Work Measurement Program, which addresses development, maintenance, and use of direct labor methods and standards, indirect labor factors, labor efficiency factors, and SFDs. The essential guide to using maintenance metrics. Work measurement leads to the development of labor and equipment time standards that are used for • estimating work-force and equipment capacity, • establishing budgets, • determining what new work procedures will cost, • evaluating time and cost trade-offs among process design alternatives, • establishing wage-incentive systems, • monitoring and evaluating employee … They are your benchmarks, the numbers against which you compare your performance. This metric varies from process to process, and as bad as 22% Emergency Work may seem — and it is not a good number when compared with many world-class operations — the fact is that a large percentage of maintenance organizations actually do far worse, for a variety of reasons. If mills perform hands-on-tools or other types of work measurements as a way to measure maintenance efficiency, they are doing the wrong thing. Follow these steps when defining metrics: Make sure to get feedback from a variety of stakeholders, like technicians, operators, and managers, to gain a better sense of which business processes need to be measured and why. Average days to complete work orders. Work measurement is very important for promoting productivity of an organization. Connect with other Fiix users from around the world, Discover guides full of practical insights and tools, Read how other maintenance teams are using Fiix, Get the latest maintenance news, tricks, and techniques. The reason is that management needs complete and timely information in order to run its business, so the work order needs to be completed while the job is fresh in the technician’s mind. Get help, give help, and spark new ideas to navigate digital transformation. It’s important, however, not to put all your eggs in one basket. On the contrary, it often creates animosity. Leverage the cloud to work together, better in the new connected age of maintenance and asset