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Maintenance Metrics

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kaskerrigan

The document discusses maintenance metrics and how to effectively use them. It covers the purpose of metrics which is to drive improvement, set priorities and establish goals. It emphasizes knowing your audience and only communicating metrics that directly affect them. Various types of metrics are defined including MTBF, PM completion rates, and inventory turns. The presentation stresses focusing on key metrics, setting goals, understanding how metrics are influenced, and celebrating successes to drive results. Presentation techniques including using charts to show trends are also covered.

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Maintenance Council Maintenance Metrics An AFE Maintenance Council Presentation Presenter: Kate Kerrigan AFE Presentation: Maintenance Metrics 1
Maintenance Council Maintenance Metrics • Purpose of Metrics • Know your audience • Metrics: How to drive to Success • Presentation Techniques AFE Presentation: Maintenance Metrics 2
Maintenance Council Purpose of Metrics AFE Presentation: Maintenance Metrics 3
Maintenance Council Purpose of Metrics • Drive Improvement – Eliminate or minimize problems – Save money – Create capacity • Set Priorities – Establish goals and how they are measured – Create common priority among diverse depts – Set milestones and celebrate success AFE Presentation: Maintenance Metrics 4
Maintenance Council Purpose of Metrics If you don’t know where you are going, any road will take you there. "Would you tell me, please, which way I ought to go from here?" "That depends a good deal on where you want to get to," said the Cat. "I don't much care where--" said Alice. "Then it doesn't matter which way you go," said the Cat. AFE Presentation: Maintenance Metrics 5
Maintenance Council Know Your Audience AFE Presentation: Maintenance Metrics 6
Maintenance Council Types of Audience • Maintenance • Other Supervisors • Managers • Production • Supervisors • Warehouse • Planners • Customers • Crew – Internal • Managers • Operators • Peers • Quality • Bosses – External • Functional • Service shops • Indirect • Facility Users AFE Presentation: Maintenance Metrics 7
Maintenance Council Know your Audience • Many metrics are appropriate for multiple audiences • Use no more than 3 metrics as a communication tool to each audience • Only communicate a metric that the audience is directly effected by • Maintenance managers and supervisors need to know all metrics and when to apply them AFE Presentation: Maintenance Metrics 8
Maintenance Council Metrics and Their Definitions • Understand the formula used by each metric – Only compare like to like – Do not depend on your CMMS unless you understand the formula used • Do not let industrial maintenance be confused with a service shop • Mentoring others is a responsibility • There is no silver bullet AFE Presentation: Maintenance Metrics 9
Maintenance Council Metrics for Managers • Maintenance Cost / Unit – Total $ spent in Maint / Units produced – This is needed to help set budgets – Trend • Determine if maintenance is getting more efficient. • Can be misleading if volumes swing dramatically. – Different organizations put different costs in maintenance, do not use this to compare outside your organization • Customer Satisfaction – Need vs Want – Equipment as the Customer AFE Presentation: Maintenance Metrics 10
Maintenance Council Overall Equipment Effectiveness (OEE) • It provides an overall evaluation of how capital assets are utilized Good Units Produced (Total units – Quality Defects) Total Units asset is * 100 = OEE capable of producing Need to define – Availability & Expected Capability AFE Presentation: Maintenance Metrics 11
Maintenance Council Mean Time Between Failure-MTBF • Mean of What – Individual machine (Widget Maker #3, Turbine 2) – Category of machines (Presses, Box Formers, …) – Sub-systems (Pumps, Conveyors, …) – Component (Bearings, Prox Switches, …) • What is a Failure – Each Work order (are PMs included?) – Breakdowns only – Work order over a Dollar or Time Threshold AFE Presentation: Maintenance Metrics 12
Maintenance Council Metrics For Maintenance • PM or PdM on time completion Rate – On-time should be within 10% of Frequency • Monthly should be done within 3 days of due date • Weekly on the due date – Goal should be between 90-100% on time – Correlate with Breakdowns • If breakdowns are not decreasing, PM program not working • Percent of total time spent by Work Order Type – Need to account for 100% of maintenance time for this to be useful – Long term indicator of Reactive or Proactive Maintenance AFE Presentation: Maintenance Metrics 13
Maintenance Council Planning Metrics • Mean time to repair (MTTR) • Backlog – usually in hours • Schedule Attainment • Planning effectiveness – Dollars – Time – Priority or RIME Ranking Index for Maintenance Expenditures (RIME) AFE Presentation: Maintenance Metrics 14
Maintenance Council Facility Metrics • Maintenance Dollars as a percent of Replacement Asset Value – Total Facility (Measure of Efficiency and Upkeep) – To determine repair/rebuild/swap/replace • Energy usage – Water consumption – Electricity consumption – Steam or Compressed Air Cost • Environmental – Waste hauling fees or tons AFE Presentation: Maintenance Metrics 15
Maintenance Council Inventory Metrics • Spare Parts – Capital or Emergency Spares (e.g. a transformer) • Unit cost • Spare for how many users/entities – Wear items • Inventory Turns • Total inventory value • Stock Outs • Life of critical components (Reliability) – Free issue stock (often vendor managed) • Total Value AFE Presentation: Maintenance Metrics 16
Maintenance Council How to Drive Success AFE Presentation: Maintenance Metrics 17
Maintenance Council Metrics: How to drive to Success • Stay Focused – Choose your driving metrics and stick with them – Publish results timely (weekly, monthly, quarterly) • Set a goal – Involve others when setting goal – Set stretch but realistic goals – If measuring is new, set escalating goal to get quick results AFE Presentation: Maintenance Metrics 18
Maintenance Council Driving Success • Understand how metric is influenced – Know the calculation formula – Have complementary metrics to avoid “pencil whipping” or sacrificing long term gains for short term ones • PM completion rate & Break Down Frequency • % Work Proactive & Response to Call time • Always know “why” when metric changes dramatically (Down or Up) AFE Presentation: Maintenance Metrics 19
Maintenance Council Driving Success • Comment on Results – Celebrate Milestones – Pep talk Failures to reach objectives • Make metric meaningful to user – Ex: 5 minutes of downtime = $1,000 • Delve into reliability – Infant Mortality – Chronic Failures (Bad Actors) – Skills Reviews and Training AFE Presentation: Maintenance Metrics 20
Maintenance Council Plan time to Analyze • Goal • Gap to Goal • How Maintenance Metrics Contribute to overall success • How do metrics fit into reliability strategy AFE Presentation: Maintenance Metrics 21
Maintenance Council Presentation Techniques AFE Presentation: Maintenance Metrics 22
Maintenance Council Chart vs List • Charts – Show trends – Very visual – Good for Quick reference – Limited Data Points • Lists – Can be sorted many ways – Require good audience understanding of values – Good for detailed reviews AFE Presentation: Maintenance Metrics 23
Maintenance Council Comparative Information • Goal Lines – Set Target – Show Gaps • Previous Time Period (Year’s) Results • Linear Trend Slope – Climbing or Descending – Sharp or Gradual • Best in Class Results (Internal or External) AFE Presentation: Maintenance Metrics 24
Maintenance Council Keep it Simple Average Maintenence Schedule Attainment By Crew Busy 100% 90% 80% 70% A Crew 60% B Crew 50% 40% Day Crew 30% 20% 10% 0% e 6 4 1 8 6 3 23 30 13 20 27 11 18 25 15 22 29 13 20 27 ag 4/ 5/ 6/ 6/ 7/ 8/ 3/ 3/ 4/ 4/ 4/ 5/ 5/ 5/ 6/ 6/ 6/ 7/ 7/ 7/ er Av Crazy Maintenence Schedule Attainment By Crew A Crew B Crew 100% Day Crew 90% Goal 80% Linear (A Crew) 70% 60% Linear (Day Crew) 50% Linear (B Crew) 40% 30% 20% 10% 0% e 6 4 1 8 6 3 23 30 13 20 27 11 18 25 15 22 29 13 20 27 ag 4/ 5/ 6/ 6/ 7/ 8/ 3/ 3/ 4/ 4/ 4/ 5/ 5/ 5/ 6/ 6/ 6/ 7/ 7/ 7/ er Av AFE Presentation: Maintenance Metrics 25
Maintenance Council Colors Schedule Attainment Weekly 2009 100% 50% 0% J J J J J F F F F M M M M A A A A A M M M M J J J J J J J J J A A A A Actual 85.9% 88.4% 67.6%80.0% 89.8% 78.8% 83.8% 72.1% 80.0% 63.9% 68.8% 57.8% 82.0% 82.8% 76.9% 78.9% 75.9% 77.1% 83.9% 80.0% 82.6%83.9% Goal 80.5% 80.5% 80.5% 80.5% 80.5% 81.0% 81.0% 81.0% 81.0% 81.0% 81.5% 81.5% 81.5% 82.0% 82.0% 82.0%82.0% 82.0% 82.5% 82.5% 82.5% 82.5% 83.0% 83.0% 83.0%83.0% 83.0% 83.5% 83.5% 83.5% 83.5% 84.0% 84.0% 84.0%84.0% 84.0% AFE Presentation: Maintenance Metrics 26
Maintenance Council Ascending vs Descending Stock Outs Stock Outs 20 Jan Feb Mar Apr May Jun Jul Aug Sep Oct 20 15 15 10 Bearings 10 Bearings 5 5 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct 0 Safety Work Orders Safety Work Orders % Complete % Not Done 100 50 80 40 60 30 40 20 20 10 0 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec AFE Presentation: Maintenance Metrics 27
Maintenance Council Dashboards • Several charts on one publication AFE Presentation: Maintenance Metrics 28
Maintenance Council Types of Charts • Line /Bar – Most Straightforward • Pie Chart – Used to compare to total amounts • Radar Chart – Used to plot several non-competing numbers AFE Presentation: Maintenance Metrics 29
Maintenance Council Lists and Data • Bad Actor Equipment • Inventory items over $xxx • Training by Employee • Breakdowns avoided by PdM • Number of trouble calls by Area AFE Presentation: Maintenance Metrics 30
Maintenance Council Effective Metrics • Know your audience – Show them something they care about – Show them something they can effect • Drive Results – You get what you measure – Do something with your information • Present for effect – Tell a story – Make your impact quickly AFE Presentation: Maintenance Metrics 31
Maintenance Council Questions? AFE Presentation: Maintenance Metrics 32

More Related Content

Maintenance Metrics

  • 1. Maintenance Council Maintenance Metrics An AFE Maintenance Council Presentation Presenter: Kate Kerrigan AFE Presentation: Maintenance Metrics 1
  • 2. Maintenance Council Maintenance Metrics • Purpose of Metrics • Know your audience • Metrics: How to drive to Success • Presentation Techniques AFE Presentation: Maintenance Metrics 2
  • 3. Maintenance Council Purpose of Metrics AFE Presentation: Maintenance Metrics 3
  • 4. Maintenance Council Purpose of Metrics • Drive Improvement – Eliminate or minimize problems – Save money – Create capacity • Set Priorities – Establish goals and how they are measured – Create common priority among diverse depts – Set milestones and celebrate success AFE Presentation: Maintenance Metrics 4
  • 5. Maintenance Council Purpose of Metrics If you don’t know where you are going, any road will take you there. "Would you tell me, please, which way I ought to go from here?" "That depends a good deal on where you want to get to," said the Cat. "I don't much care where--" said Alice. "Then it doesn't matter which way you go," said the Cat. AFE Presentation: Maintenance Metrics 5
  • 6. Maintenance Council Know Your Audience AFE Presentation: Maintenance Metrics 6
  • 7. Maintenance Council Types of Audience • Maintenance • Other Supervisors • Managers • Production • Supervisors • Warehouse • Planners • Customers • Crew – Internal • Managers • Operators • Peers • Quality • Bosses – External • Functional • Service shops • Indirect • Facility Users AFE Presentation: Maintenance Metrics 7
  • 8. Maintenance Council Know your Audience • Many metrics are appropriate for multiple audiences • Use no more than 3 metrics as a communication tool to each audience • Only communicate a metric that the audience is directly effected by • Maintenance managers and supervisors need to know all metrics and when to apply them AFE Presentation: Maintenance Metrics 8
  • 9. Maintenance Council Metrics and Their Definitions • Understand the formula used by each metric – Only compare like to like – Do not depend on your CMMS unless you understand the formula used • Do not let industrial maintenance be confused with a service shop • Mentoring others is a responsibility • There is no silver bullet AFE Presentation: Maintenance Metrics 9
  • 10. Maintenance Council Metrics for Managers • Maintenance Cost / Unit – Total $ spent in Maint / Units produced – This is needed to help set budgets – Trend • Determine if maintenance is getting more efficient. • Can be misleading if volumes swing dramatically. – Different organizations put different costs in maintenance, do not use this to compare outside your organization • Customer Satisfaction – Need vs Want – Equipment as the Customer AFE Presentation: Maintenance Metrics 10
  • 11. Maintenance Council Overall Equipment Effectiveness (OEE) • It provides an overall evaluation of how capital assets are utilized Good Units Produced (Total units – Quality Defects) Total Units asset is * 100 = OEE capable of producing Need to define – Availability & Expected Capability AFE Presentation: Maintenance Metrics 11
  • 12. Maintenance Council Mean Time Between Failure-MTBF • Mean of What – Individual machine (Widget Maker #3, Turbine 2) – Category of machines (Presses, Box Formers, …) – Sub-systems (Pumps, Conveyors, …) – Component (Bearings, Prox Switches, …) • What is a Failure – Each Work order (are PMs included?) – Breakdowns only – Work order over a Dollar or Time Threshold AFE Presentation: Maintenance Metrics 12
  • 13. Maintenance Council Metrics For Maintenance • PM or PdM on time completion Rate – On-time should be within 10% of Frequency • Monthly should be done within 3 days of due date • Weekly on the due date – Goal should be between 90-100% on time – Correlate with Breakdowns • If breakdowns are not decreasing, PM program not working • Percent of total time spent by Work Order Type – Need to account for 100% of maintenance time for this to be useful – Long term indicator of Reactive or Proactive Maintenance AFE Presentation: Maintenance Metrics 13
  • 14. Maintenance Council Planning Metrics • Mean time to repair (MTTR) • Backlog – usually in hours • Schedule Attainment • Planning effectiveness – Dollars – Time – Priority or RIME Ranking Index for Maintenance Expenditures (RIME) AFE Presentation: Maintenance Metrics 14
  • 15. Maintenance Council Facility Metrics • Maintenance Dollars as a percent of Replacement Asset Value – Total Facility (Measure of Efficiency and Upkeep) – To determine repair/rebuild/swap/replace • Energy usage – Water consumption – Electricity consumption – Steam or Compressed Air Cost • Environmental – Waste hauling fees or tons AFE Presentation: Maintenance Metrics 15
  • 16. Maintenance Council Inventory Metrics • Spare Parts – Capital or Emergency Spares (e.g. a transformer) • Unit cost • Spare for how many users/entities – Wear items • Inventory Turns • Total inventory value • Stock Outs • Life of critical components (Reliability) – Free issue stock (often vendor managed) • Total Value AFE Presentation: Maintenance Metrics 16
  • 17. Maintenance Council How to Drive Success AFE Presentation: Maintenance Metrics 17
  • 18. Maintenance Council Metrics: How to drive to Success • Stay Focused – Choose your driving metrics and stick with them – Publish results timely (weekly, monthly, quarterly) • Set a goal – Involve others when setting goal – Set stretch but realistic goals – If measuring is new, set escalating goal to get quick results AFE Presentation: Maintenance Metrics 18
  • 19. Maintenance Council Driving Success • Understand how metric is influenced – Know the calculation formula – Have complementary metrics to avoid “pencil whipping” or sacrificing long term gains for short term ones • PM completion rate & Break Down Frequency • % Work Proactive & Response to Call time • Always know “why” when metric changes dramatically (Down or Up) AFE Presentation: Maintenance Metrics 19
  • 20. Maintenance Council Driving Success • Comment on Results – Celebrate Milestones – Pep talk Failures to reach objectives • Make metric meaningful to user – Ex: 5 minutes of downtime = $1,000 • Delve into reliability – Infant Mortality – Chronic Failures (Bad Actors) – Skills Reviews and Training AFE Presentation: Maintenance Metrics 20
  • 21. Maintenance Council Plan time to Analyze • Goal • Gap to Goal • How Maintenance Metrics Contribute to overall success • How do metrics fit into reliability strategy AFE Presentation: Maintenance Metrics 21
  • 22. Maintenance Council Presentation Techniques AFE Presentation: Maintenance Metrics 22
  • 23. Maintenance Council Chart vs List • Charts – Show trends – Very visual – Good for Quick reference – Limited Data Points • Lists – Can be sorted many ways – Require good audience understanding of values – Good for detailed reviews AFE Presentation: Maintenance Metrics 23
  • 24. Maintenance Council Comparative Information • Goal Lines – Set Target – Show Gaps • Previous Time Period (Year’s) Results • Linear Trend Slope – Climbing or Descending – Sharp or Gradual • Best in Class Results (Internal or External) AFE Presentation: Maintenance Metrics 24
  • 25. Maintenance Council Keep it Simple Average Maintenence Schedule Attainment By Crew Busy 100% 90% 80% 70% A Crew 60% B Crew 50% 40% Day Crew 30% 20% 10% 0% e 6 4 1 8 6 3 23 30 13 20 27 11 18 25 15 22 29 13 20 27 ag 4/ 5/ 6/ 6/ 7/ 8/ 3/ 3/ 4/ 4/ 4/ 5/ 5/ 5/ 6/ 6/ 6/ 7/ 7/ 7/ er Av Crazy Maintenence Schedule Attainment By Crew A Crew B Crew 100% Day Crew 90% Goal 80% Linear (A Crew) 70% 60% Linear (Day Crew) 50% Linear (B Crew) 40% 30% 20% 10% 0% e 6 4 1 8 6 3 23 30 13 20 27 11 18 25 15 22 29 13 20 27 ag 4/ 5/ 6/ 6/ 7/ 8/ 3/ 3/ 4/ 4/ 4/ 5/ 5/ 5/ 6/ 6/ 6/ 7/ 7/ 7/ er Av AFE Presentation: Maintenance Metrics 25
  • 26. Maintenance Council Colors Schedule Attainment Weekly 2009 100% 50% 0% J J J J J F F F F M M M M A A A A A M M M M J J J J J J J J J A A A A Actual 85.9% 88.4% 67.6%80.0% 89.8% 78.8% 83.8% 72.1% 80.0% 63.9% 68.8% 57.8% 82.0% 82.8% 76.9% 78.9% 75.9% 77.1% 83.9% 80.0% 82.6%83.9% Goal 80.5% 80.5% 80.5% 80.5% 80.5% 81.0% 81.0% 81.0% 81.0% 81.0% 81.5% 81.5% 81.5% 82.0% 82.0% 82.0%82.0% 82.0% 82.5% 82.5% 82.5% 82.5% 83.0% 83.0% 83.0%83.0% 83.0% 83.5% 83.5% 83.5% 83.5% 84.0% 84.0% 84.0%84.0% 84.0% AFE Presentation: Maintenance Metrics 26
  • 27. Maintenance Council Ascending vs Descending Stock Outs Stock Outs 20 Jan Feb Mar Apr May Jun Jul Aug Sep Oct 20 15 15 10 Bearings 10 Bearings 5 5 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct 0 Safety Work Orders Safety Work Orders % Complete % Not Done 100 50 80 40 60 30 40 20 20 10 0 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec AFE Presentation: Maintenance Metrics 27
  • 28. Maintenance Council Dashboards • Several charts on one publication AFE Presentation: Maintenance Metrics 28
  • 29. Maintenance Council Types of Charts • Line /Bar – Most Straightforward • Pie Chart – Used to compare to total amounts • Radar Chart – Used to plot several non-competing numbers AFE Presentation: Maintenance Metrics 29
  • 30. Maintenance Council Lists and Data • Bad Actor Equipment • Inventory items over $xxx • Training by Employee • Breakdowns avoided by PdM • Number of trouble calls by Area AFE Presentation: Maintenance Metrics 30
  • 31. Maintenance Council Effective Metrics • Know your audience – Show them something they care about – Show them something they can effect • Drive Results – You get what you measure – Do something with your information • Present for effect – Tell a story – Make your impact quickly AFE Presentation: Maintenance Metrics 31
  • 32. Maintenance Council Questions? AFE Presentation: Maintenance Metrics 32