maintenance key performance indicators

Not

es

2. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'

ID Ratio Numerator Ratio Denominator

Tactical Goal

1 Lag Cost Lag Cost Fixed asset ratioTotal Maintenance Cost X 100% Assets Replacement Value Year BSI E1

2 Lag Cost Lead Cost

Total Maintenance Cost Quantity of output Year/ Quarter BSI E3

3 Lag Cost Lead Cost Inventory ratioAsset Replacement Value Year/ Quarter

4 Lead Lead Cost Contractor cost ratioTotal contractor cost X 100% Total Maintenance Cost Optimise BSI E10

5 Lead Lead Cost Stores turnoverTotal cost of maintenance materials Trend up Year/ Quarter BSI E12

6 Lead Lead Shutdown ratioMaintenance shutdown cost X 100% Total Maintenance Cost Year BSI E20

7 Lag Availability Lead AvailabilityRequired time Month BSI T2

Maintenance Performance Indicators (Typical Measures or Metrics) © 2009 Shire Systems Ltd

1. To gain further information on the special nature of lagging and leading indicators of performanceand their critical differences , view the Shire slideshow 'Lean Maintenance'

Engineering Manager Role Perspective

Business Manager Role Perspective Indicator's Typical

Name

Indicator Typical Target Value

Indicator Typical

Reporting Period

Comment (Any BSI

designations refer to BSI

15341)Lead or Lag

Lead or Lag

Strategic Goal

2 to 4, trend down

Maintenace cost per unit produced

Trend down

Average inventory value of maintenance materials X 100%

Trend down

Availability versus Cost

Month/ Quarter


Average inventory value of maintenance materials

Availability, Cost

Delivery, Cost

Trend down

Quality, Delivery,

Cycle, Cost

Achieved up time during required time X 100%

Trend up, target > 95%

B6

With respect to the Role of the Engineering Manager

G7

Total Maintenance Cost is the total allocatable cost of the maintenace organisation with espect to the Assets. That is, including all direct & indirect personnel & materials and company overheads

H7

The asset Replacement Value (ARV) is the estimated amount of capital that would be required to build/replace the Asset. The ARV can be eqivalent to the insurance value.

F8

Per unit of finished product or service delivered

G10

Contractors are used to cover specialist tasks and peaks of normal task activities. There is an optimum ratio for each organistion in consideration of overall productivity/cost. Contractors should be employed on a 'fixed price' or 'measured work' basis. 'Reimbursable hours' contacts shouldt be avoided.

G12

Shutdown maintenance is that carried out when a whole plant or factory is shutdown, for example, the annual shutdown with a power outage.

G13

The up state is the state when an item can perform a required function at capacity

H13

The time interval during which the user requires the item to be in a condition to perform a required function. If an operational schedule is not used, calendar time can be used as a coarse measure

8 Lag Availability NA NA

Total Operating time Trend up Month

9 Lag Lead

Total Operating time Number of failures causing downtime Trend up Month BSI T17

10 Lag Lead Failure frequencyLoading time Month

11 Lag Lead Failure severity rateTotal stoppage time due to failure X 100% Loading time Month

12 Lead NA NA Risk Analysis ratio

Total number of systems 10 to 15 BSI T18

13 Lead NA NA Planning ratio5 to 10 Month BSI T19

14 Lead NA NA

15 Lag Lead

Total time to restoration Number of failures Month BSI T21

16 Lead Lead

Trend up Month BSI O4

17 Lead Cost NA NA

Total maintenance man-hours available Trend up Month BSI O5

18 Lead NA NA

5 to 10 Month BSI O8

Mean time between downtime work-orders

Number of maintenance work-orders causing downtime

Availability, Cost,

Compliance

Quality, Delivery,

Cycle, Cost

MTBF (Mean Time Between

Failure)

Availability, Cost,

Compliance

Quality, Delivery,

Cycle, Cost

Total number of plant stoppages due to failure

Trend down

Availability, Cost,

Compliance

Delivery, Cycle Time,

Cost

0.15. Trend down

Availability, Cost,

Compliance, Capability

Number of systems covered by a critical analysis X 100%

Month/ Quarter

Availability, Cost,

Compliance

Man-hours used for planning in a systematic maintenance planning process X 100%

Total internal maintenance personnel man-hours

Availability, Cost,

Compliance

Condition monitoring coverage ratio

Number of assets in the condition monitoring program X100%

Total number of candidate items for condition monitoring

20 Trend up

Month/ Quarter

See: Condition-based maintenance ratio BSI O19

Availability, Compliance


CostMTTR

(Mean Time To Repair)

Trend down

Availability, Cost,

Compliance

Quality, Delivery,

Cycle, Cost

Auto-maintenance ratio (Autonomous

Maintenance)

Production operator maintenance man-hours X 100%

Total direct maintenance personnel man-hours

Planned & Scheduled Work ratio

Planned and scheduled maintenance man-hours X 100%

Availability, Cost,


Continuous improvement ratio

Man-hours for continuous improvement X 100%

Total maintenance personnel man-hours

G14

If an operational schedule is not used, calendar time can be used as a coarse measure

H14

All maintenace types - Corrective, Preventive, improvement.

F15

Undoubtedly, the most important indicator of maintenance performance

G16

Count stoppages lasting 10 minutes or more

G19

Planning includes safety considerations, labour, materials, tools & equipment, an estimate of the downtime & man-hours to complete the work, etc.

G21

The sum of the times to restoration, that is the sum of the times an item is in the down state due to failure. It INCLUDES administrative and logistic delays.

G23

Includes all maintenace - Routine, Corrective, Preventive, Condition-based and Improvement

G24

Man-hours consumed on processes intended to improve the current level of availability, reliability, maintainability, quality, safety, environment and costs. Includes time spent on critical analyses and auditing.

19 Lead Lead Shift cover ratio

Total direct maintenance personnel Minimise Quarter/ Year BSI O10

20 Lead Lead Multiskilled ratioMaximise

21 Lead NA NA

Total maintenance man-hours Month BSI O16

22 Lead NA NA

Total maintenance man-hours Month BSI O17

23 Lead NA NA

Month

24 Lead NA NA PM Routine IncidenceTotal number of major assets/systems Quarter

25 Lead NA NA

Total maintenance man-hours Trend up Month BSI O18

26 Lead NA NA PM performanceNumber of PM jobs completed X 100% Number of PM jobs scheduled Target 100 Month

27 Lead NA NA

Total maintenance man-hours Trend up Month BSI O19

28 Lead NA NA Schedule complianceTotal number of scheduled work orders Month BSI O22

29 Lead NA NA Training ratioTotal internal maintenance man-hours 3 to 5 BSI O23

Cost versus Availability

Quality, Delivery,

Cycle Time versus Cost

Direct maintenance personnel on shift X 100%

Availability, Cost


Cost

Number of internal Multi-skilled maintenance personnel X 100%

Number of internal maintenance personnel

Month/ Quarter

BSI O15. First Fix capability, especially on shift

Availability, Cost,

Compliance

Corrective maintenance ratio

Corrective maintenance man-hours X 100%

Trend down

Availability, Cost,

Compliance

Emergency maintenace man-hour ratio

Immediate Corrective maintenance man-hours X 100%

Trend down, < 10

Availability, Cost,

Compliance

Emergency maintenace work order ratio

Number of Immediate Corrective maintenance work-orderscompleted X 100%

Total number or maintenace work-orders completed

Trend down, < 10

Availability, Cost,

Compliance

Number of major assets/systems with PM routines

Target 100%

Availability, Cost,

Compliance

Preventive maintenace ratio

Preventive maintenance man-hours X 100%

Availability, Cost,

Compliance

Availability, Cost,

Compliance

Condition-based maintenance ratio

Condition based maintenance man-hours X 100%

Availability, Cost,

Compliance

Number of work orders performed as scheduled X 100%

Trend up, target 100%

Availability, Cost,

Compliance

Number of maintenance internal personnel man-hours for training X 100%

Nmonth/ Quarter

30 Lead NA NA CMMS usage ratioQuarter/ Year BSI O24

31 Lead NA NA Backlog age Stable Month

32 Lead NA NA

Month

33 Lag NA NA

Average age of equipment Average useful life of equipment Year

34 Lead NA NA Plant renovation rate

Cost of replacing obsolete items X 100% Total cost of maintenance 15 to 20 Quarter/ Year

35 Lag NA NA Materials/Labour ratioTotal cost of direct labour To target Month

36 Lead NA NA Manpower utilisationTrend up Month

37 Lead Lag

Month

38 Lead Lag

Month

39 Lead Lag Service levelTotal number of service calls Month

40 Lead NA NA

Month

Availability, Cost,

Compliance

Number of internal direct maintenance people using software X 100%

Number of internal direct maintenance personnel

Target 100%


Number of approved work orders over 3 months old

Total number of incomplete work orders


Work backlog (man weeks)

Total estimated manhours for all outstanding work orders

Actual available hours to schedule each week

To target. Say, about 4 man weeks

Availability, Cost,


Equipment obsolescence ratio

To target. Stable or trend down

Availability, Cost,


Cost (Productivity)

Total cost of maintenance materials X 100%

Cost (Productivity)

Total internal direct man-hours worked X 100%

Total internal direct man-hours available


Quality, Delivery,

Cycle, Cost

Response time - Emergency service calls

Cumulative response time of all Emergency priority service calls

Total number of Emergency priority service calls

Trend down or stable


Quality, Delivery,

Cycle, Cost

Response time - Urgent service calls

Cumulative response time to all Ugent priority service calls

Total number of Urgent priority service calls



Quality, Delivery,

Cycle, Cost

Number of service calls within the target response time

Trend up or stable


Fix/Make-Safe time - Emergency priority

service calls

Cumulative Fix/Make-Safe repair time of all Emergency priority service calls



G36

BSI specification is the number of workers using CMMS for at least 5% of their working time

G37

Choose another more appropriate period, as required

41 Lead NA NA Rework rateNumber of rework jobs X 100% Total number of jobs Month

42 Lag Lead/Lag Satisfaction IndexAS DEFINED AS DEFINED Trend up Month

43 Lead NA NA Work-order volumeTotal number of work orders registered None Month

44 Lead NA NA Work-order backlog Total number of outstanding work orders None Stable Month

45 Lead NA NANone Stable Month

46 Lag Lag Plant failure rateNone Month

47 Lead NA NA

None To target Month

48 Lag NA NATotal direct man-hours worked None Month

49 Lag Lag Cost Contractor cost trendTotal cost of contractors None To target Quarter

50 Lag Lag Cost Inventory trendTotal value of parts inventory None Quarter

Indicators can check the same parameter from different perspectives

Availability, Cost,

Compliance

Trend down

Availability, Cost,

Compliance

Quality, Delivery





Work-order completion rate

Total number of work orders completed during the period

Availability, Cost,

Compliance

Quality, Delivery,

Cycle, Cost

Number of unexpected equipment failures resulting in downtime

Trend down

Availability, Cost,


Continuous improvement trend

Number of man-hours on continuous improvenment activity

Availability, Cost,

Compliance

Internal direct man-hour trend

Trend down



Trend down

Notes: 1. These indicators have been selected from the list on the Maintenance Indicator tab of this Workbook

3. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'

ID Ratio Numerator

Lead or Lag Tactical Goal Strategic Goal

4 Lead Lead Cost Contractor cost ratioOptimise Month/ Quarter BSI E10

5 Lead Lead Cost Stores turnover

Trend up Year/ Quarter BSI E12

6 Lead Availability, Cost Lead Delivery, Cost Shutdown ratio

Trend down Year BSI E20

12 Lead NA NA Risk Analysis ratio

10 to 15 Month/Quarter BSI T18

13 Lead NA NA Planning ratio

5 to 10 Month BSI T19

Leading Indicators of Maintenance Performance - Engineering Manager's perspective © 2009 Shire Systems Ltd

2. To gain further information on the special nature of lagging and leading indicators of performance, view the Shire slideshow 'Lean Maintenance'

Engineering Manager Role Perspective

Business Manager Role Perspective Indicator's Typical

NameRatio

Denominator Indicator Typical

Target Value

Indicator Typical

Reporting Period

Comment (Any BSI

designations refer to BSI

15341)Lead or Lag


Total contractor cost X 100%

Total Maintenance Cost


Total cost of maintenance materials

Average inventory value of maintenance materials

Maintenance shutdown cost X 100%

Total Maintenance Cost

Availability, Cost, Compliance,

Capability

Number of systems covered by a critical analysis X 100%

Total number of systems

Availability, Cost, Compliance

Man-hours used for planning in a systematic maintenance planning process X 100%

Total internal maintenance personnel man-hours

A6

See Note 1 of this Worksheet

B7

With respect to the Role of the Engineering Manager

C8

There's a trade-off between Cost and Availability

G8

Contractors are used to cover specialist tasks and peaks of normal task activities. There is an optimum ratio for each organistion in consideration of overall productivity/cost. Contractors should be employed on a 'fixed price' or 'measured work' basis. 'Reimbursable hours' contacts must be avoided.

G10

Shutdown maintenance is that carried out when a whole plant or factory is shutdown, for example, the annual shutdown with a power outage. See the Shire Whitepaper on Shutdown planning

G12

Planning includes safety considerations, labour, materials, tools & equipment, an estimate of the downtime & man-hours to complete the work, etc.

14 Lead NA NA

Month/ Quarter

16 Lead Lead


17 Lead Cost NA NA


18 Lead NA NA

5 to 10 Month BSI O8

19 Lead Lead Shift cover ratio

Minimise Quarter/ Year BSI O10

20 Lead Availability, Cost Lead Multiskilled ratio

Maximise Month/ Quarter

21 Lead NA NA

Trend down Month BSI O16


Condition monitoring coverage

ratio



20 Trend up

See: Condition-based maintenance ratio BSI O19


Quality, Delivery, Cycle, Cost

Operator maintenance ratio

Production operator maintenance man-hours X 100%

Total direct maintenance personnel man-hours

Planned & Scheduled Work

ratio

Planned and scheduled maintenance man-hours X 100%

Total maintenance man-hours available


Capability

Continuous improvement ratio

Man-hours for continuous improvement X 100%

Total maintenance personnel man-hours

Cost versus Availability

Quality, Delivery, Cycle Time versus Cost

Direct maintenance personnel on shift X 100%

Total direct maintenance personnel

Delivery, Cycle Time, Cost

Number of internal Multi-skilled maintenance personnel X 100%

Number of internal maintenance personnel

BSI O15. First Fix capability, especially on shift


Corrective maintenance ratio

Corrective maintenance man-hours X 100%

Total maintenance man-hours

G15

Includes all maintenace - Routine, Corrective, Preventive, Condition-based and Improvement

G16

Man-hours consumed on processes intended to improve the current level of availability, reliability, maintainability, quality, safety, environment and costs. Includes time spent on critical analyses and auditing.

22 Lead NA NA

Month BSI O17

23 Lead NA NA

Month

24 Lead NA NA

Target 100% Quarter

25 Lead NA NA


26 Lead NA NA PM performanceTarget 100 Month

27 Lead NA NA


28 Lead NA NA

Month BSI O22


Emergency maintenace man-

hour ratio

Immediate Corrective maintenance man-hours X 100%


Trend down, < 10


Emergency maintenace work

order ratio

Number of Immediate Corrective maintenance work-orderscompleted X 100%

Total number or maintenace work-orders completed

Trend down, < 10


PM Routine Incidence

Number of major assets/systems with PM routines

Total number of major assets/systems


Preventive maintenace ratio

Preventive maintenance man-hours X 100%



Number of PM jobs completed X 100%

Number of PM jobs scheduled


Condition-based maintenance ratio

Condition based maintenance man-hours X 100%



Schedule compliance

Number of work orders performed as scheduled X 100%

Total number of scheduled work orders

Trend up, target 100%

29 Lead NA NA Training ratio

3 to 5 Month/Quarter BSI O23

30 Lead NA NA CMMS usage ratio

Target 100 Quarter/ Year BSI O24

31 Lead NA NA Backlog age

Stable Month

32 Lead NA NA

Month

34 Lead NA NA Plant renovation rate

15 to 20 Quarter/ Year

36 Lead Cost (Productivity) NA NA Manpower utilisation

Trend up Month

37 Lead Lag

Month


Number of maintenance internal personnel man-hours for training X 100%

Total internal maintenance man-hours


Number of internal direct maintenance people using software X 100%

Number of internal direct maintenance personnel



Total number of incomplete work orders





To target. Say, about 4 man weeks


Capability

Cost of replacing obsolete items X 100%

Total cost of maintenance


Total internal direct man-hours available



Response time - Emergency service

calls

Cumulative response time of all Emergency priority service calls



G28

BSI specification is the number of workers using CMMS for at least 5% of their working time

G29

Choose another more appropriate period, as required

38 Lead Lag

Month

39 Lead Lag Service level

Month

40 Lead NA NA

Month

41 Lead NA NA Rework rate

Trend down Month

43 Lead NA NA Work-order volume

None Month

44 Lead NA NA Work-order backlog

None Stable Month

45 Lead NA NA

None Stable Month

47 Lead NA NA

None To target Month



Response time - Urgent service calls

Cumulative response time to all Ugent priority service calls

Total number of Urgent priority service calls





Total number of service calls

Trend up or stable


Fix/Make-Safe time - Emergency priority

service calls

Cumulative Fix/Make-Safe repair time of all Emergency priority service calls




Number of rework jobs X 100%

Total number of jobs


Total number of work orders registered



Total number of outstanding work orders



Total number of work orders completed during the period


Capability

Continuous improvement trend

Number of man-hours on continuous improvenment activity

Data requirements to calculate and report the BSI KPIs © 2009 Shire Systems Ltd

Work Types Corrective maintenance (Corrective + Priority 1 = Breakdown)Preventive maintenance (at fixed intervals)Predetermined maintenance (without a previous condition inspection)Condition based maintenance (predictive)Improvement maintenance (improving the dependability of an item without changing its function)TrainingPlanningContinuous improvementRoutineModification (changing the required function of an item)Project

Work Priority Priority 1 (respond immediately)Others

Failure consequence Environmental damagePotential environmental damageInjury to personsPotential injury to persons

Up

Down - failure (breakdown) times must be loggedDown - preventive maintenanceDown - predetermined maintenanceDown - condition based maintenanceDown - Shutdown (planned outage) Down - other

To enable the reporting of performance, input data must be compatible. The following attributes of maintenace works must be recorded:

Plant up/down state during maintenace

B5

Maintenance carried out to correct a recorded fault

System/Asset Analysed Not analysed

Personnel resource InternalContractors

Trades/Employee Group Mechanical (Note: sum of all internal tradespersons can be assumed to be the direct internal personnel)ElectricalInstrumentationMultiskilledProduction operator

Use of CMMS Number of direct internal maintenance people using the CMMS for more than 5% of their working time

Complement Total maintenance personnel (direct + indirect) List all maintenance staff in system, divided between direct and indirectTotal number of employees (in the enterprise)

B33

Technical analysis - FMEA/RCM, etc

A45

Computerised Maintenance Management Sytem

Area/Group Level ID Numerator Denominator Comment

Turmover ratioTotal cost of maintenance X100% Net sales turnover Year

Plant availabilityTotal hours in the reporting time period 96

< 2 Month

Emergency job rateTotal emergency jobs worked X 100% Total jobs worked Month

20 Quarter/ Year

Thermography surveyNumber of faults found X100% Number of devices surveyed < 3 Quarter/ Month

Steam trap surveyNumber of steam traps surveyed < 10 Quarter/ Month

Month

PM performanceNumber of PM jobs completed X 100% Number of PM jobs scheduled Month

Overdue PMNone Month

Month

Work-order volumeTotal number of work orders registered None Month

Work-order backlog Total number of outstanding work orders None Month

Other Maintenance KPIs & Metrics © 2009 Shire Systems Ltd

Indicator's Typical Name

Applicable Sectors

Typical Target Value

Typical Reporting

Period

Hours the equipment was available to run at capacity X 100%

Overtime rate - indirect internal personnel

Total overtime manhours worked by indirect maintenance personnel during period X 100%

Total regular manhours of indirect maintenance personnel during period

Condition monitoring coverage



Number of defective steam traps found X 100%

Age of backlog work-orders


Number of overdue PM work orders at the end of the period




~4 man weeks

None Month

Month

Total actual cost of work X 100% Total estimated cost of work within ± 10 Quarter

Total cost of all jobs Quarter/ Month

Plant renovation rateCost of replacing obsolete items X 100% Total cost of maintenance 15 to 20 Year

Average age of equipment Average useful life of equipment Year

Total number of material requisitions Month

Material ratioTotal cost of maintenance materials Total cost of maintenance Month

Labour/materials ratioTotal cost of direct labour Month

Plant failure rateNone Month

Failure frequencyTotal number of stoppages due to failure Loading time Month

Failure severity rateTotal stoppage time due to failure X 100% Loading time 0.15

Month

PM achievementPM tasks completed X 100% PM tasks planned Month

Modifications trendNumber of modifications completed None Month


Total number of work orders closed during the period

Man-hour estimation accuracy

Total estimated man-hours for completed work orders X 100%

Total actual man-hours for completed work orders

Cost estimation accuracy

Volume of estimated work

Total cost of planned and estimated jobs X 10%

Equipment obsolescence ratio

Stores issue service level

Number of material requisitions met from stock

Total cost of maintenance materials X 100%

Number of unexpected equipment failures resulting in downtime

Emergency maintenance rate

Number of emergency maintenance jobs X 100%

Total number of preventive maintenance + emergency maintenance jobs

E27

Count stoppages lasting 10 minutes or more

None Month

Total direct man-hours worked None Month

Contractor cost trendTotal cost of contractors None Quarter

Inventory trendTotal value of parts inventories None Quarter

Manpower utilisationTotal internal direct man-hours available Quarter

Shiftwork incidenceTotal man-hours worked on shift X 100% Total man-hours worked Quarter

Total number of Priority 1 service calls Month


Response performanceTotal number of service calls Month


Rework rateNumber of rework jobs X 100% Total number of jobs Month

Satisfaction IndexAS DEFINED AS DEFINED

Modifications proposed trend

Number of modification proposals registered

Internal direct man-hour trend


Response time - Priority 1 service calls

Cumulative response time of all Priority 1 service calls

Response time - Priority 2 services calls

Cumulative response time to all Priority 2 service calls


Fix/Make Safe time - Priority 1

Cumulative Fix/Make Safe repair time of all Priority 1 service calls

maintenance key performance indicators

Documents

pm routine incidence

based maintenance ratio

bsi designations refer

approved work orders

pm jobs completed

cmms usage ratio

continuous improvement ratio

condition based maintenance