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A Guide To Maintenance Metrics-Program

This document discusses several key performance indicators (KPIs) for maintenance. It describes downtime as tracking the total time equipment is unavailable, with the aim being less than 10% downtime. Planned maintenance percentage considers time spent on planned maintenance activities divided by total maintenance time. Schedule compliance analyzes adherence to the preventive maintenance plan, which should be over 90%. The document also discusses total maintenance costs, maintenance percentage of replacement asset value to evaluate spending, and stock turn ratio to measure inventory investment effectiveness.

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92 views

A Guide To Maintenance Metrics-Program

This document discusses several key performance indicators (KPIs) for maintenance. It describes downtime as tracking the total time equipment is unavailable, with the aim being less than 10% downtime. Planned maintenance percentage considers time spent on planned maintenance activities divided by total maintenance time. Schedule compliance analyzes adherence to the preventive maintenance plan, which should be over 90%. The document also discusses total maintenance costs, maintenance percentage of replacement asset value to evaluate spending, and stock turn ratio to measure inventory investment effectiveness.

Uploaded by

Ly Quan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Downtime

This maintenance indicator tracks, monitors and evaluates the asset’s reliability.

Downtime tracks the total time equipment was unavailable or offline, which

means an undesired event occurred and it will require some kind of intervention.

You can use this KPI whether there’s already a maintenance plan in place for

that asset or not. It’s also a variation of the Planned Maintenance Percentage,

which we’ll cover below.

Your aim for this key performance indicator should be 10%. This means the

asset should be fully operational (also called “uptime”) around 90% of time so

that production won’t shut down. The lack of infrastructure, monitoring and

planning are usually what drives higher downtime percentages.

This indicator can help you establish a preventive maintenance strategy with

the goal of keeping downtime below average, as well as minimizing the effect

of unplanned shutdowns. Remember that when an asset isn’t working, there

isn’t any output – which ultimately leads to losses.

PMP – Planned Maintenance Percentage


The planned maintenance percentage considers the time spent on planned

activities (maintenance, repairs or replacements) on an asset. This maintenance

KPI is directly linked to the company’s Preventive Maintenance Plan.

We take into account effectiveness, compliance and how each activity was

performed, as well the time needed to complete it. Then, simply divide the total

planned maintenance hours by the total maintenance hours. Multiply the result

by 100 to get the percentage.

Schedule Compliance/ Planned Maintenance Compliance


This KPI could not be missing from a list with the most important key

performance indicators in maintenance. In short, it analyses the compliance

with the plan you’ve established.

Or, better yet, the effectiveness and commitment technicians and managers

showed on their planned tasks. Schedule compliance as a maintenance KPI

measures the whole team’s performance, from the decision-makers to the people

who comply with the plan day in and day out.


How many activities were performed according to the established guidelines?

Generally, managers evaluate the date, the time it took to complete a task and

efficiency. Compliance should be 90% or more.

Using this indicator and assuring it falls within the average (or above) means

that productivity is high, with minimal failure risks and losses


This result shows the level of effectiveness of the company, as well as

its performance and success within its sector. To match global median

values, PMP should be around 85% or above.


total maintenance cost (including labour, materials, maintenance contracts);

Maintenance percentageof replacement asset value (MPRAV) What is it?Maintenance percentage of


replacement asset value (MPRAV) tells you how much you are spending on maintenance compared to the value of
the asset. It measures how well you are doing at creating and maintaining a cost effective maintenance strategy.
MPRAV takes into account two different elements: The cost of maintenance and an asset’s replacement value.
Calculating MPRAV doesn’t take into account other costs for production, disposal, etc.How is it measured?The
formula for MPRAV uses two measurements: One for maintenance costs and one for replacement
value.Maintenance costs are calculated by adding together the cost of parts, labour, and miscellaneous expenses for
all closed work orders in a time period for a particular asset. Replacement asset value is the present cost to replace
the existing asset with a new, identical asset.Ch. 03 Asset performance maintenance metrics 12Fiix A Guide to
Maintenance Metrics

MPRAV is calculated by multiplying maintenance costs by 100 and dividing the result by the replacement asset value.
BenchmarkWorld-class MPRAV: Between 2% to 3%How do I use it?To adapt your maintenance habits and spend
less. MPRAV gives you insight into the areas of your operation where you can spend less while still providing high-
quality maintenance. For example, if MPRAV spikes, it may mean a piece of equipment is breaking down more
frequently, which means more labour hours and emergency parts. You may need to schedule more preventive
maintenance, order more parts, and provide training on a certain kind of failure to reduce the impact on the bottom
line. Keeping an eye on MPRAV is more important as an asset ages and the decision to repair or replace it grows
closer.Ch. 03 Asset performance maintenance metrics13Fiix A Guide to Maintenance Metrics

Stock turn ratio (STR)


Good inventory management often leads to good maintenance. When the right part is in the
right location, it enables a technician to do a task as fast and completely as possible. This
section investigates inventory metrics so you can arm yourself with the information you need to
make better decisions about spare parts and help your maintenance operation excel. Stock
turn ratio (STR)What is it?Stock turn ratio measures the effectiveness of your investment in
spare parts. It calculates whether the money you’ve spent on inventory is actually making an
impact on your facility, or if it’s sitting idle on storeroom shelves. STR tells you if you have over-
invested in inventory as a whole and indicates if you have the right mix of inventory.Ch. 04
Maintenance metrics for inventory14Fiix A Guide to Maintenance Metrics

How is it measured?Stock turn ratio is calculated by dividing the dollar value of


inventory issued in the past year by the dollar value of inventory held when the measure
is taken. For example, if a company holds $5M of inventory today and has issued $2.5M
of inventory in the past year, the STR is 0.5 (it has turned over its inventory investment at
the rate of one half per year).BenchmarkWorld-class STR: 2.5How do I use it?To spend
your inventory budget better. Stock turn ratio can help you investigate your investment
in spare parts and spot operational inefficiencies in the way you purchase, track, and use
inventory. For example, a stock turn ratio of 0.5 is typical, but low, and indicates a plant
that is overstocked, especially if stock outs are also low. If stock outs are high and the
STR is low, a facility is probably investing in inventory that isn’t being used, while
lacking in-demand stock. STR targets are influenced by a number of controllable and
uncontrollable issues, such as inventory purchasing processes and the location of the
facility.

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