maintenance benchmarking (3)

European Maintenance Std.

Benchmarking

Maintenance Models

- RCM

- CCFI

- Integration Model - TPM

Development of Maintenance

Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering

© All Rights Reserved 2003

Methods toOptimization

- Implementation

Benchmarking in

Maintenance


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation *24 Hours/Day, 240 Days/Year**also through Material shortage and Operator/Personnel, New Product Introductions, etc.(Value in principal not known, calculated according to production Time

Source: McKinsey & DIN 8743

%

ESTIMATIONS

50 to 70

65 to 80

10 to 20100

5 to 15

0 to 540 to 605 to 10

Total Time*

Planned Time

Break-down Time

Set-up Time

Available Time

ShortInter-ruptions**

ProductiveTime

Material Flow Problems

Scrap, ReworkTime

ActualProduction Time

10 to 15

Unplanned Time • Breakdown Times are often not considered due to the larger % Available Time.

• Set-up & Change Over Times are dependant on lot sizes and frequency.

Hours and Weeks must

be known

Plant Availability


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Breakdown Potential

Downtime %

Ave. (Breakdown free) Utilization

Ave. Breakdown Rate

Maintenance Benchmarking

Plant Operating Time

Plant DowntimeX 100

Number of Breakdowns

Plant Utilization Time

Amount of Breakdowns

Sum of Breakdown Periods


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Building Partnerships, i.e. Networking With whom can you benchmark?

technology institutes universities consultants other companies in different industries having

similar systems. other sister branches your competitors Yourself, over time.

Source: VDI 2886, a guide to “Benchmarking Design”


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Efficiency:

Availability: Availability = (Planned production time - Unscheduled

Downtime)/Planned production timeThe Production time = Planned production time - Downtime

Output rate/Performance: The Performance = Cycle time x number of products processed/

Production timeNow remains the Net Production time (= time products are produced)

Quality rate/Yield: The Yield (Quality Rate) = (# processed products - # rejected

products)/(# processed products)

OEE (Overall Equipment Efficiency) = Availability x Output rate x Quality rate Or OEE = tcycle ( # parts finished - # parts for rework – # scrap parts)

Tplanned or available

The OEE index has been developed by the JIPM (Japan Institute for Plant Maintenance).

Source: http://www.tpfeurope.com/EN_OEEinfo.html Source: Al-Rahdi: TPM


http://www.tpfeurope.com/EN_OEEinfo.html

http://www.tpfeurope.com/EN_OEEinfo.html


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Benchmarking Maintenance Strategies

Inspection Intensity

Maintenance Intensity

Preventive Intensity

Repair Portion


total Maintenance Cost

Inspection CostX 100

Cleaning CostX 100

Planned Maintenance CostX 100

total Maintenance Work hours Repair due to breakdown (in h.)

X 100




Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Benchmarking Maintenance Procedures

Maintenance Efficiency

Reaction Degree

Plan-work time of executed WorkX 100

Number of Maintenance Orders

Justified executed Maintenance OrdersX 100

Actual-work time of executed Work



Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Benchmarking Maintenance Resources

Contractor Quota

Personnel Intensity

Maintenance Personnel-Portion

Capacity Degree

Total Maintenance CostContractor Cost

X 100

Maintenance Personnel

Plant Value

Production Personnel

Maintenance personnelX 100

Maintenance Capacity (in h.)total planned Orders (in h.)

X 100



Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Benchmarking Spare Parts

Spares Coverage

Spares Intensity

Spares Coverage(in Months)

Spares Store ValueX 100

Ave. Usage of Spare parts during last 12 Months

Spot check value of Spare parts

Maintenance Costs

Booked-out Value of Spare parts/yearX 100

Value of total Spare Part Store (Stock)



Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Benchmarking Maintenance

Turnover vs.Maintenance Cost Quota

Production Volume vs. Maintenance Cost Quota

Maintenance Cost Factor

Self Cost Portion

Turnover Volume

total Maintenance CostX 100

Production Volume

Total Maintenance Cost

Plant Setup CostX 100


Own Cost PortionX 100




Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Benchmarking Maintenance Costs

Contractor Quota

Material Cost Portion

Personnel Cost Portion

Maintenance Cost Rate


Contractor CostX 100


Material CostX 100


Maintenance Personnel CostX 100

total Work Hours




Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Industry Related Maintenance Cost Benchmarking

0

10

20

30

40

50

60

70

Automotive AutomotiveSup.

Chemical Electrical Power Gen. Mechanical

Maint. Cost-rate Contractors

Material Personnel

%


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Industrial Reflection of Effective Plant Utilization

56,3 4,5 12,6 12,3 14,3

31,900,5

12 55,7

60,5 16,8 22,3 9,5

61,32,2

4,6 16,7 15,3

59,6 4 9,9 23,9 2,6

57,52,4 2,8

21,4 16

0% 20% 40% 60% 80% 100%

Mec

hani

cal E

ng.

Aut

omot

ive

Effective Plant Utilization Quality LossesMaterial flow- &. C/Over Losses Availability LossesCapacity Losses


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

maintenance benchmarking (3)

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