Tec – 709

Maintenance Engineering

Maintenance KPI

Prof: John Santana

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KPI = Key Performance Indicator

Objectives

• Improve personnel’s understanding of KPIs and what

they indicate.

+ ` =

• Improve personnel’s awareness of maintenance

performance.
 What is a KPI?
KPIs track performance against established key success factors.

• KPIs are directly linked to the overall goals of the company.

• Business Objectives are defined at corporate, regional and site level. These
goals determine critical activities (Key Success Factors) that must be done well
for a particular operation to succeed.
• KPIs are utilised to track or measure actual performance against key success
factors.
– Key Success Factors (KSFs) only change if there is a fundamental shift in business objectives.
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– Key Performance Indicators (KPIs) change as objectives are met, or management focus shifts.

Business Key Success Key Performance

Objectives Factors (KSFs) Indicators (KPIs)
Determine. Tracked by.

No Injuries Safety LTI, LTIFR, LTISR.

 How do I interpret a KPI?
Interpretation of KPIs is KPI dependent.
KPIs do NOT give answers, rather they raise questions and direct attention.

Business Key Success Key Performance

Objectives Factors (KSFs) Indicators (KPIs)
Determine. Tracked by.

No Injuries Safety LTI, LTIFR, LTISR.

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• If LTI, LTIFR or LTISR increase, this indicates that the business objective, “No
Injuries”, is NOT being fulfilled.
– This should direct attention to the SAFETY key success factor.
– Problems / Issues should be identified and resolved with a view to decreasing safety KPIs and
therefore achieving the business objective.

• If LTI, LTIFR or LTISR decrease, this indicates that the business objective, “No
Injuries”, is being fulfilled.
– This indicates safety practices / mechanisms are proving successful.
What influence do I have on KPIs?
Every person on-site has an influence on certain KPIs and business objectives.

Senior Foremen Crew

• LTIFR • LTIFR
• Incidents • Incidents
• Property damage ($) • Property damage ($)
• Cost / unit • Mean time to repair
• Cost / hour `
• Cost of quality
• Maintenance effectiveness
• Maintenance efficiency
• Mean time between failure
• Mean time to repair
Maintenance KPIs
Seventeen (17) primary maintenance KPIs to be utilised.
– These KPIs will be utilised across the site’s Maintenance Departments.

KPIs
• LTIFR (both production and maintenance) • Backlog
• Maintenance Cost per Unit vs. Budget • % Scheduled Man Hours Planned
• Maintenance Cost per Hour vs. Budget • % Schedule Compliance
• Cost of Quality ` • % Planning Effectiveness
• Maintenance Effectiveness • % Man Hours Available
• Maintenance Efficiency • % Rework
• Mean Time Between Failure (MTBF) • % Failures Investigated
• Mean Time to Repair (MTTR) • MIP Process Effectiveness
• Preventive Inspection Effectiveness
• Ratio of Preventive to Breakdown Maintenance
LTIFR
Lost Time Injury Frequency Rate
• LTIFR is a measure of overall safety performance, and indicates the frequency
of Lost Time Injuries (LTIs).
LTIFR = 
Number of Lost Time Injuries 
Formula  x 1,000,000
 Total M an Hours 

– Total man hours includes wages, staff and contractor hours associated with both production and
maintenance operations.

• Personnel are getting injured.

• Safety practices / mechanisms are ineffective.
• Incident reporting is increasing.

Interpretation LTIFR < 5

• Personnel are NOT getting injured.
• Safety practices / mechanisms are effective.
• Incident reporting is reducing.
Maintenance Cost per Unit vs. Budget
• A measure of the maintenance effort required for a piece of equipment (or
plant) to generate a unit of production.
T o ta l M a in te n a n c e C o st
Formula M a in te n a n c e C o st p e r U n it =
U n it o f P ro d u c tio n

– Total maintenance cost includes total costed maintenance man hours, parts and any other costs
associated with the maintenance effort (preventive and corrective).
– Unit of production will match the associated departments current unit.

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• Maintenance effort required is increasing.
• Maintenance practices / mechanisms are ineffective.
• Operating conditions are deteriorating.
• Equipment is being over maintained.
• Maintenance cost budgeting was inaccurate.
Interpretation • Maintenance requirements changed during the fiscal year.

Maintenance Cost per Unit vs. Budget

• Maintenance effort required is decreasing.
• Maintenance practices / mechanisms are effective.
• Operating conditions are improving.
• Maintenance cost budgeting was inaccurate.
• Maintenance requirements changed during the fiscal year.
Maintenance Cost per Hour vs. Budget
• A measure of the maintenance effort required to generate production time
from a piece of equipment (or plant).
T o tal M ain ten an ce C o st
Formula M ain ten an c e C o st p er H o u r =
O p eratin g T im e

– Total maintenance cost includes total costed maintenance man hours, parts and any other costs
associated with the maintenance effort (preventive and corrective).
– Operating time is productive time plus production delays.

• Maintenance effort required is increasing.

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• Maintenance practices / mechanisms are ineffective.
• Operating conditions are deteriorating.
• Equipment is being over maintained.
• Maintenance cost budgeting was inaccurate.
• Maintenance requirements changed during the fiscal year.
• Budgeted operating time reduced.

Interpretation Maintenance Cost per Hour vs. Budget

• Maintenance effort required is decreasing.
• Maintenance practices / mechanisms are effective.
• Operating conditions are improving.
• Maintenance cost budgeting was inaccurate.
• Maintenance requirements changed during the fiscal year.
• Budgeted operating time increased.
Cost of Quality
• A measure of preventive maintenance effect on corrective and total
maintenance costs.

Concept

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Cost of Quality (cont.)
– Total maintenance cost, or cost of quality, is the sum of preventive and corrective maintenance
costs.
– Preventive maintenance cost is the cost associated with maintenance carried out at
predetermined intervals or other prescribed criteria intended to reduce the probability of failure
or degradation of performance of equipment (or plant).
– Corrective maintenance cost is the cost associated with maintenance carried out on a defect
which has caused equipment (or plant) to be taken out of service during scheduled operating
time. Corrective maintenance can be either planned or unplanned.

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• Preventive maintenance effort decreasing.
• Corrective maintenance effort increasing.
• Preventive maintenance effort excessive (beyond optimum).
Interpretation • Maintenance practices / mechanisms are ineffective.

Cost of Quality
• Preventive maintenance effort is increasing.
• Corrective maintenance effort in decreasing.
• Preventive to corrective maintenance ratio optimised.
• Maintenance practices / mechanisms are effective.
Maintenance Effectiveness
• A measure of the amount of maintenance downtime required to keep
equipment (or plant) operating.
 O perating Tim e 
Formula M aintenance Effectiveness =   x 100%
 O perating Tim e + D ow n Tim e 

– Operating time is productive time plus production delays.

– Down time is the total time equipment (or plant) is down for maintenance work (preventive and
corrective).

• Maintenance effort required is decreasing.

• Maintenance practices / mechanisms are effective.
• Operating conditions are improving.

Interpretation Maintenance Effectiveness > 95%

• Maintenance effort required is increasing.
• Maintenance practices / mechanisms are ineffective.
• Operating conditions are deteriorating.
• Equipment is being over maintained.
Maintenance Efficiency
• A measure of the maintenance effort required to deliver required
performance levels from equipment (or plant).
 M aintenance M an H ours 
Formula M aintenance E fficiency = 
 O perating T im e
 x 100%


– Maintenance man hours is the actual maintenance man hours spent maintaining an item of
equipment (or plant). Maintenance man hours includes maintenance wages, staff and contractor
hours (preventive and corrective).
– Operating time is productive time plus production delays.

• Maintenance effort required is increasing.

• Maintenance practices / mechanisms are ineffective.
• Operating conditions are deteriorating.
• Equipment is being over maintained.

Interpretation Maintenance Efficiency

• Maintenance effort required is decreasing.
• Maintenance practices / mechanisms are effective.
• Operating conditions are improving.
MTBF
Mean Time Between Failure
• The average amount of operating time between consecutive breakdowns for
an item of equipment (or plant).
O perating T im e
Formula M TBF =
N um ber of F ailures o r B reakdow n E vents

– Operating time is productive time plus production delays.

– Number of failures or breakdown events is the number of failures on an item of equipment (or
plant).
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• Maintenance effort required is decreasing.

• Maintenance practices / mechanisms are effective.
• Failure frequency is decreasing.
• Operating conditions are improving.

Interpretation MTBF
• Maintenance effort required is increasing.
• Maintenance practices / mechanisms are ineffective.
• Failure frequency is increasing.
• Operating conditions are deteriorating.
MTTR
Mean Time To Repair
• The average maintenance time required to keep an item of equipment (or
plant) operational.
D o w n T im e
Formula M TTR =
N u m b er o f F ailu res o r B reak d o w n E v en ts

– Down time is the total time equipment (or plant) is down for maintenance work (preventive and
corrective).
– Number of failures or breakdown events is the number of failures on an item of equipment (or
plant). `

• Maintenance practices / mechanisms are ineffective.

• Poor clean-up (work preparation) practices.
• Ineffective work practices.

Interpretation MTTR

• Maintenance practices / mechanisms are effective.

• Clean-up (work preparation) practices effective.
• Effective work practices.
Preventive Inspection Effectiveness
Ratio of Preventive Repair Man Hours to Preventive Inspection Man Hours.
• A measure of preventive inspection effectiveness.
P re v e n tiv e R e p a ir M a n H o u rs
Formula P re v e n tiv e In s p e c tio n E ffe c tiv e n e s s =
P re v e n tiv e In s p e c tio n M a n H o u r s

– Preventive repair man hours is maintenance that is performed as a result of a preventive

inspection.
– Preventive inspection man hours is work performed that originates from equipment maintenance
strategies; ie. planned services and inspections.
`

• Preventive inspections are effective.

• Inspection frequency to low.
• Preventive inspection conducted effectively.

Preventive Inspection Effectiveness

Interpretation
• Preventive inspections are ineffective.
• Preventive inspections are conducted ineffectively.
• Inspection frequency to high.
Ratio of Preventive to Breakdown Maintenance
Ratio of Preventive Man Hours to Breakdown Man Hours.
• A measure of planning / scheduling process effectiveness and its influence on
breakdown maintenance.
Formula R a tio o f P re v e n tiv e
to B re a k d o w n M a in te n a n c e =
P re v e n tiv e R e p a ir M a n H o u rs + P re v e n tiv e In s p e c tio n M a n H o u rs
B re a k d o w n M a n H o u rs

– Preventive repair man hours is maintenance that is performed as a result of a preventive inspection.
– Preventive inspection man hours is work performed that originates from equipment maintenance
strategies; ie. planned services and inspections.
– Breakdown man hours is unplanned corrective maintenance that must occur due to a defect causing
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equipment (or plant) to be taken out of service during scheduled operating time (NOT corrective
maintenance man hours).

• Over maintaining equipment.

• Preventive maintenance practices / strategies are too
effective and should be optimised (optimise costs).

Interpretation Ratio of Preventive to Breakdown Maintenance = 16

• Preventive inspections are ineffective.

• Faults not being reported.
• Preventive maintenance practices / strategies are ineffective.
Backlog
• All maintenance work identified to be done, but as yet incomplete. Indicates
how much outstanding maintenance work exists compared to the resources
available to complete the work.
• Formula B a c k lo g = T o ta l M a in te n a n c e M a n H o u rs o n O u ts ta n d in g W o rk O rd e rs

– Total maintenance man hours on outstanding work orders currently includes both backlog and
forward log.

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• Build up of jobs.
• Insufficient labour.
• Maintenance practices / mechanisms are ineffective.
• Preventive inspections are effective (Work identified).

Interpretation Backlog < 1,800 man hours

• Preventive inspections are ineffective (No work identified).
• Too much labour.
• Maintenance practices / mechanisms are effective.
% Scheduled Man Hours Planned
• The percentage of scheduled man hours that appear on the weekly schedule
that have been planned. A measure of planning process effectiveness.
• Formula % S c h e d u le d M a n H o u r s P la n n e d =


P la n n e d M a n H o u rs o n W e e k ly S c h e d u le 
 x 100%
 T o ta l W e e k ly S c h e d u l e d M a n H o u r s 

– Planned man hours on weekly schedule is the total planned maintenance hours on the weekly
maintenance schedule.
– Total weekly scheduled man hours is the total maintenance man hours scheduled for the week
(NOT total maintenance man hours available).

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• High level of planned work in backlog.
• Minimal job delays.
• Maintenance practices / mechanisms are
effective.
• Too much labour.
Interpretation % Scheduled Man Hours Planned > 80%
• Priority work not being planned.
• Lack of planned work in backlog.
• Maintenance practices / mechanisms are ineffective.
• Insufficient labour.
% Scheduled Compliance
• A measure of scheduling process compliance.
 S c h e d u le d M a n H o u rs C o m p le te d 
Formula % S c h e d u le d C o m p lia n c e =   x 100%
 T o ta l W e e k ly S c h e d u le d M a n H o u rs 

– Scheduled man hours completed is the actual man hours spent performing scheduled
maintenance.
– Total weekly scheduled man hours is the total maintenance man hours scheduled for the week
(NOT total maintenance man hours available).

• Priority jobs being completed.

• Planned repairs, PM’s being executed.
• Maintenance practices / mechanisms are effective.
`
• Too much labour.
• Effective work practices.
• Maintenance / Production Department communication /
cooperation effective (Access to equipment).
• Insufficient scheduled man hours to conduct maintenance.

Interpretation % Scheduled Compliance > 80%

• High level of breakdowns / interruptions.
• Maintenance practices / mechanisms are ineffective.
• Insufficient labour.
• Maintenance / Production Department communication /
cooperation ineffective (Access to equipment).
• Ineffective work practices.
• To many scheduled man hours to conduct maintenance.
% Planning Effectiveness
• A measure of planning process compliance.
 N u m b e r o f S c h e d u le d J o b s C o m p le te d w ith C o m m e n ts 
Formula % P la n n in g E f f e c tiv e n e s s =   x 100%
 T o ta l N u m b e r o f S c h e d u le d J o b s C o m p le te d 

– Number of scheduled jobs completed with comments is the number of scheduled jobs
completed with comments on the job ticket identifying issues / problems with the planning
process.

• Minimum requirements for a planned job not understood.

• Schedule compliance low.
• High level of job delays. `
• Maintenance practices / mechanisms are ineffective.
• Maintenance / Production Department communication /
cooperation ineffective (Access to equipment).

% Planning Effectiveness < 20%

Interpretation
• Planned requirements well understood.
• Schedule compliance high.
• Maintenance practices / mechanisms are effective.
• Maintenance / Production Department communication /
cooperation effective (Access to equipment).
• Job ticket comments not being completed.
% Man Hours Available
• Primarily a measure of attendance, but also a useful tool to track training and
future manpower requirements. Indicates effective utilisation of man power.
% M an Hours Available = 
• Formula Total M an Hours Paid - Absence from W ork 
 x 100%
 Total M an Hours Paid 

– Absence from work is man hours associated with absenteeism, training and any other diversion
from an employees primary function.

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• Lack of employee development.
• Lack of training.
• Reduction in absenteeism.
• Core function (maintenance) being fulfilled.
Interpretation % Man Hours Available
• Absenteeism.
• Excessive training.
• Core function (maintenance) not being fulfilled.
% Rework
• Maintenance action that is a repeat of a previous, ineffective effort. The work
could have been ineffective due to poor workmanship, poor design, or
improper procedures.
% Rew ork =   x 100%
• Formula Rew ork M an H ours
 M aintenance W ork H ours 

– Rework man hours is man hours associated with a maintenance action that is a repeat of a
previous, ineffective effort.
– Maintenance man hours is the actual maintenance man hours spent maintaining an item of
equipment (or plant). Maintenance man hours includes maintenance wages, staff and contractor
hours (preventive and corrective). `

• Maintenance practices / mechanisms are ineffective.

• Poor design.
• Poor operating practices.
• Ineffective work practices.
Interpretation
% Rework < 20%
• Maintenance practices / mechanisms are effective.
• Effective work practices.
• Good design.
% Failures Investigated
• Measure of the Maintenance Department’s effort to continuously improve.
% F ailu res In v estig a ted = 
N u m b er o f C o rrectiv e Jo b T ick e ts In v estig ated 
Formula  x 100%
 T o tal N u m b er o f C o rrectiv e Jo b T ick ets 

– Number of corrective job tickets investigated is the number of job tickets investigated, root cause
found, and solutions investigated to prevent future occurrences. Job tickets that are associated
with maintenance work performed on defects which caused equipment (or plant) to be taken out
of service during scheduled operating time.
– Total number of corrective job tickets is the total number of job tickets associated with
maintenance work performed on defects which caused equipment (or plant) to be taken out of
service during scheduled operating time. `

• Improved equipment reliability.

• Continuously improving maintenance
practices / mechanisms.
Interpretation % Failures Investigated > 80%
• Repetitive equipment failures.
• Repetitive job delays.
• Continuous improvement of maintenance practices /
mechanisms is not occurring.
MIP Process Effectiveness
• Measure of the Maintenance Department’s effort to continuously improve.
Concept

– MIP process effectiveness is a combination of the maintenance KPIs, schedule compliance,

planning effectiveness and backlog.

`
• Maintenance effort is improving.
• Maintenance mechanisms / practices are improving.
• Improved equipment reliability.
• Backlog is decreasing.

Interpretation MIP Process Effectiveness > 80%

• Maintenance effort is deteriorating.
• Maintenance mechanisms / practices are not improving.
• Equipment reliability is deteriorating.
• Backlog is increasing.
Summary
KPIs track performance against established key success factors.

Interpretation of KPIs is KPI dependent.

KPIs do NOT give answers, rather they raise questions and direct attention.

Every person on-site has an influence on certain KPIs and business objectives.

Seventeen (17) primary maintenance KPIs to be utilised.

`
–These KPIs will be utilised across the site’s Maintenance Departments.

• Systems and mechanism implemented to address business objectives (key

success factors) can always be improved.
– A continuous improvement (CI) philosophy should be adopted.