maintenance key performance indicators
TRANSCRIPT
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2. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'
Ratio Numerator Ratio Denominator
Tactical Goal
Lag Cost Lag Cost Fixed asset ratioAssets Replacement Value Year BSI E1
2 Lag Cost Lead Cost
Total Maintenance Cost Quantity of output Trend down BSI E3
3 Lag Cost Lead Cost Inventory ratio
Asset Replacement Value Trend down
4 Lead Lead Cost Contractor cost ratio
Total contractor cost X 100% Total Maintenance Cost Optimise BSI E10
5 Lead Lead Cost Stores turnover
Total cost of maintenance materials Trend up BSI E12
6 Lead Lead Shutdown ratio
Total Maintenance Cost Trend down Year BSI E20
7 Lag Availability Lead Availability
Required 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
IND 1
Total Maintenance Cost X 100%
2 to 4, trend down
Maintenace cost per unit produced
Year/ Quarter
Average inventory value of maintenance materials X 100%
Year/ Quarter
Availability versus Cost
Month/ Quarter
Availability versus Cost
Average inventory value of maintenance materials
Year/ Quarter
Availability, Cost
Delivery, Cost
Maintenance shutdown cost X 100%
Quality,
Delivery,
Cycle, Cost
Achieved up time during required time X 100%
Trend up, target > 95%
8 Lag Availability NA NA
Total Operating time Trend up Month
9 Lag Lead
Total Operating time Trend up Month BSI T17
10 Lag Lead Failure frequency
Loading time Trend down Month
11 Lag Lead Failure severity rate
Loading time Month
12 Lead NA NA Risk Analysis ratio
Total number of systems 10 to 15 BSI T18
13 Lead NA NA Planning ratio
5 to 10 Month BSI T19
14 Lead NA NA
15 Lag Lead
Total time to restoration Number of failures Trend down Month BSI T21
16 Lead Lead
Trend up Month BSI O4
17 Lead Cost NA NA
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)
Number of failures causing downtime
Availability, Cost,
Compliance
Quality,
Delivery,
Cycle, Cost
Total number of plant stoppages due to failure
Availability, Cost,
Compliance
Delivery,
Cycle Time, Cost
Total stoppage time due to failure X 100%
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
Delivery,
Cycle Time, Cost
MTTR (Mean Time To Repair)
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%
Total maintenance man-hours available
Availability, Cost,
Compliance, Capability
Continuous improvement ratio
Man-hours for continuous improvement X 100%
Total maintenance personnel man-hours
19 Lead Lead Shift cover ratio
Total direct maintenance personnel Minimise BSI O10
20 Lead Lead Multiskilled ratio
Maximise
21 Lead NA NA
Total maintenance man-hours Trend down 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 Incidence
Target 100% Quarter
25 Lead NA NA
Total maintenance man-hours Trend up Month BSI O18
26 Lead NA NA PM performance
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 compliance
Month BSI O22
29 Lead NA NA Training ratio
3 to 5 BSI O23
Cost versus Availability
Quality,
Delivery,
Cycle Time
versus Cost
Direct maintenance personnel on shift X 100%
Quarter/ Year
Availability, Cost
Delivery,
Cycle Time, 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%
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
Total number of major assets/systems
Availability, Cost,
Compliance
Preventive maintenace ratio
Preventive maintenance man-hours X 100%
Availability, Cost,
Compliance
Number of PM jobs completed X 100%
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%
Total number of scheduled work orders
Trend up, target 100%
Availability, Cost,
Compliance
Number of maintenance internal personnel man-hours for training X 100%
Total internal maintenance man-hours
Nmonth/ Quarter
30 Lead NA NA CMMS usage ratio
Target 100% 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
Lead NA NA Plant renovation rate
Total cost of maintenance 15 to 20
35 Lag NA NA Materials/Labour ratio
Total cost of direct labour To target Month
36 Lead NA NA Manpower utilisation
Trend up Month
37 Lead Lag
Month
38 Lead Lag
Month
39 Lead Lag Service level
Total 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
Quarter/ Year
Availability, Compliance
Number of approved work orders over 3 months old
Total number of incomplete work orders
Availability, Compliance
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,
Compliance, Capability
Equipment obsolescence ratio
To target. Stable or trend down
IND 2
Availability, Cost,
Compliance, Capability
Cost of replacing obsolete items X 100%
Quarter/ Year
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
Availability, Compliance
Quality, Deliver
y, 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
Availability, Compliance
Quality, Deliver
y, Cycle, Cost
Response time - Urgent service calls
Cumulative response time to all Ugent priority service calls
Total number of Urgent priority service calls
Trend down or stable
Availability, Compliance
Quality, Deliver
y, Cycle, Cost
Number of service calls within the target response time
Trend up or stable
Availability, Compliance
Fix/Make-Safe time - Emergency priority
service calls
Cumulative Fix/Make-Safe repair time of all Emergency priority service calls
Total number of Emergency priority service calls
Trend down or stable
41 Lead NA NA Rework rate
Number of rework jobs X 100% Total number of jobs Trend down Month
42 Lag Lead/Lag Satisfaction Index
AS DEFINED AS DEFINED Trend up 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
46 Lag Lag Plant failure rate
None Trend down Month
47 Lead NA NA
None To target Month
48 Lag NA NA
Total direct man-hours worked None Trend down Month
49 Lag Lag Cost Contractor cost trend
Total cost of contractors None To target Quarter
50 Lag Lag Cost Inventory trend
Total value of parts inventory None Trend down Quarter
Indicators can check the same parameter from different perspectives
Availability, Cost,
Compliance
Availability, Cost,
Compliance
Quality, Deliver
y
Availability, Compliance
Total number of work orders registered
Trend down or stable
Availability, Compliance
Total number of outstanding work orders
Availability, Compliance
Work-order completion rate
Total number of work orders completed during the period
Availability, Cost,
Compliance
Quality, Deliver
y, Cycle, Cost
Number of unexpected equipment failures resulting in downtime
Availability, Cost,
Compliance, Capability
Continuous improvement trend
Number of man-hours on continuous improvenment activity
Availability, Cost,
Compliance
Internal direct man-hour trend
Availability versus Cost
Availability versus Cost
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 ratio
Optimise 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 Name
Ratio Denominator
Indicator Typical
Target Value
Indicator Typical
Reporting Period
Comment (Any BSI
designations refer to BSI
15341)Lead or Lag
Availability versus Cost
Total contractor cost X 100%
Total Maintenance Cost
Availability versus 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
14 Lead NA NA
Month/ Quarter
16 Lead Lead
Trend up Month BSI O4
17 Lead Cost NA NA
Trend up Month BSI O5
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
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
See: Condition-based maintenance ratio BSI O19
Availability, Cost, Compliance
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
Availability, Cost, Compliance,
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
Availability, Cost, Compliance
Corrective maintenance ratio
Corrective maintenance man-hours X 100%
Total maintenance man-hours
22 Lead NA NA
Month BSI O17
23 Lead NA NA
Month
24 Lead NA NA
Target 100% Quarter
25 Lead NA NA
Trend up Month BSI O18
26 Lead NA NA PM performance
Target 100 Month
27 Lead NA NA
Trend up Month BSI O19
28 Lead NA NA
Month BSI O22
Availability, Cost, Compliance
Emergency maintenace man-
hour ratio
Immediate Corrective maintenance man-hours X 100%
Total maintenance man-hours
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
PM Routine Incidence
Number of major assets/systems with PM routines
Total number of major assets/systems
Availability, Cost, Compliance
Preventive maintenace ratio
Preventive maintenance man-hours X 100%
Total maintenance man-hours
Availability, Cost, Compliance
Number of PM jobs completed X 100%
Number of PM jobs scheduled
Availability, Cost, Compliance
Condition-based maintenance ratio
Condition based maintenance man-hours X 100%
Total maintenance man-hours
Availability, Cost, Compliance
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
Availability, Cost, Compliance
Number of maintenance internal personnel man-hours for training X 100%
Total internal maintenance man-hours
Availability, Cost, Compliance
Number of internal direct maintenance people using software X 100%
Number of internal direct maintenance personnel
Availability, Compliance
Number of approved work orders over 3 months old
Total number of incomplete work orders
Availability, Compliance
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, Compliance,
Capability
Cost of replacing obsolete items X 100%
Total cost of maintenance
Total internal direct man-hours worked X 100%
Total internal direct man-hours available
Availability, Compliance
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
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
Availability, Compliance
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
Trend down or stable
Availability, Compliance
Quality, Delivery, Cycle, Cost
Number of service calls within the target response time
Total number of service calls
Trend up or stable
Availability, Compliance
Fix/Make-Safe time - Emergency priority
service calls
Cumulative Fix/Make-Safe repair time of all Emergency priority service calls
Total number of Emergency priority service calls
Trend down or stable
Availability, Cost, Compliance
Number of rework jobs X 100%
Total number of jobs
Availability, Compliance
Total number of work orders registered
Trend down or stable
Availability, Compliance
Total number of outstanding work orders
Availability, Compliance
Work-order completion rate
Total number of work orders completed during the period
Availability, Cost, Compliance,
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
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)
List all maintenance staff in system, divided between direct and indirect
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 assets in the condition monitoring program X100%
Total number of candidate items for condition monitoring
Number of defective steam traps found X 100%
Age of backlog work-orders
Number of approved work orders over 3 months old
Number of overdue PM work orders at the end of the period
Work backlog (man weeks)
Total estimated manhours for all outstanding work orders
Actual available hours to schedule each week
~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 ratio
Total 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
Work-order completion rate
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
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
Total number of Priority 2 service calls Month
Response performanceTotal number of service calls Month
Total number of Priority 1 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
Total internal direct man-hours worked X 100%
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
Number of service calls within the target response time
Fix/Make Safe time - Priority 1
Cumulative Fix/Make Safe repair time of all Priority 1 service calls