Maintenance Performance Indicators (Typical Measures or Metrics)
Notes
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' 2. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators' Engineering Manager Role Perspective
Lead or Lag Tactical Goal
Business Manager Role Perspective
Lead or Lag
Strate gic Goal
Indicator's Typical Name
Ratio Numerator
Ratio Denominator
Indicator Typical Target Value
Indicator Typical Reporting Period
Comment
(Any BSI designations refer to BSI 15341)
IND 1 2
Lag
Cost
Lag
Cost
Total Maintenance Cost X Fixed asset ratio 100%
Total Maintenance Cost Maintenace cost per unit produced Average inventory value of maintenance materials X 100% Total contractor cost X 100%
Assets Replacement Value
2 to 4, trend down
Trend down
Year
BSI E1
Quantity of output
Lag
Cost
Lead
Cost
Year/ Quarter Year/ Quarter Month/ Quarter Year/ Quarter Year
BSI E3
Asset Replacement Value
Trend down
Lag
Cost
Lead
Cost
Inventory ratio
Total Maintenance Cost
Optimise
BSI E10
Lead
Availability versus Cost Availability versus Cost Availability, Cost
Lead
Cost
Contractor cost ratio Total cost of maintenance materials Maintenance shutdown cost X 100% Achieved up time during required time X 100% Total Operating time Average inventory value of maintenance materials Total Maintenance Cost Trend up
BSI E12
Lead
Lead
Cost Delive ry, Cost Qualit y, Delive ry, NA
Stores turnover
Trend down
BSI E20
Lead
Lead
Shutdown ratio
Required time
Lag
Availability
Lead
Availability
Trend up, target > 95% Trend up
Month
BSI T2
Lag
Availability
NA
Mean time between downtime work-orders
Number of maintenance workorders causing downtime
Month
Lag
Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance, Capability Availability, Cost, Compliance Availability, Cost, Compliance Availability, Compliance Availability, Cost, Compliance
Lead
10
Lag
Lead
11
Lag
Lead
Qualit y, Delive ry, Qualit y, Delive ry, Delive ry, Cycle Time, NA
MTBF
(Mean Time Between Failure) Failure frequency
Total Operating time
Number of failures causing downtime Loading time
Trend up
Month
BSI T17
Total number of plant stoppages due to failure Total stoppage time due to failure X 100% Number of systems covered by a critical analysis X 100%
Trend down
Month
Loading time
Failure severity rate
0.15. Trend down 10 to 15
Month
Total number of systems
12
Lead
NA
Risk Analysis ratio
Month/ Quarter
BSI T18
13
Lead
NA
NA
Planning ratio
Man-hours used for planning in a systematic maintenance planning process X 100% Number of assets in the condition monitoring program X100%
Total internal maintenance personnel man-hours Total number of candidate items for condition monitoring
5 to 10
Month
BSI T19
14
Lead
NA
NA
Condition monitoring coverage ratio
20 Trend up
Month/ Quarter
See: Conditionbased maintenance ratio BSI O19 BSI T21
15
Lag
Lead
16
Lead
Lead
17
Lead
Cost Availability, Cost, Compliance, Capability
NA
Delive Total time to restoration ry, MTTR Cycle (Mean Time To Repair) Time, Qualit Production operator maintenance y, Auto-maintenance ratio man-hours X 100% Delive (Autonomous Maintenance) ry, Planned and scheduled Planned & Scheduled maintenance man-hours X 100% NA Work ratio Man-hours for continuous improvement X 100%
Number of failures
Trend down
Month
Total direct maintenance personnel Trend up man-hours
Month
BSI O4
Total maintenance man-hours available Total maintenance personnel manhours
Trend up
Month
BSI O5
5 to 10
Month
BSI O8
18
Lead
NA
NA Qualit y, Delive ry, Cycle Time
Continuous improvement ratio
19
Lead
Cost versus Availability
Direct maintenance personnel on shift X 100% Shift cover ratio
Total direct maintenance personnel Minimise
Quarter/ Year
BSI O10
Lead
20
Lead
Availability, Cost Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Compliance
Lead
Delive ry, Cycle Time, NA
Multiskilled ratio
Number of internal Multi-skilled maintenance personnel X 100%
Number of internal maintenance personnel
Maximise
Month/ Quarter Month
21
Lead
NA
Corrective maintenance man-hours Total maintenance man-hours Corrective maintenance X 100% ratio Immediate Corrective maintenance Total maintenance man-hours Emergency maintenace man-hours X 100% man-hour ratio Number of Immediate Corrective Emergency maintenace maintenance workwork order ratio orderscompleted X 100% Number of major assets/systems PM Routine Incidence with PM routines Total number or maintenace workorders completed Total number of major assets/systems
Trend down
BSI O15. First Fix capability, especially on BSI O16
22
Lead
NA
NA
Trend down, Month < 10 Trend down, Month < 10 Target 100% Quarter
BSI O17
23
Lead
NA
NA
24
Lead
NA
NA
25
Lead
NA
NA
Preventive maintenance man-hours Total maintenance man-hours Preventive maintenace X 100% ratio Number of PM jobs completed X 100% Number of PM jobs scheduled
Trend up
Month
BSI O18
Target 100
Month
26
Lead
NA
NA
PM performance
27
Lead
NA
NA
Condition-based maintenance ratio
Condition based maintenance man- Total maintenance man-hours hours X 100% Number of work orders performed as scheduled X 100% Total number of scheduled work orders
Trend up
Month
BSI O19
28
Lead
NA
NA
Schedule compliance
Trend up, target 100% 3 to 5
Month
BSI O22
29
Lead
NA
NA
Training ratio
Number of maintenance internal Total internal maintenance manpersonnel man-hours for training X hours 100% Number of internal direct maintenance people using software X 100% Number of approved work orders over 3 months old Number of internal direct maintenance personnel Total number of incomplete work orders
Nmonth/ Quarter Quarter/ Year Month
BSI O23
Target 100%
BSI O24
30
Lead
NA
NA
CMMS usage ratio
Stable
31
Lead
NA
NA
Backlog age
32
Lead
Availability, Compliance Availability, Cost, Compliance, Capability Availability, Cost, Compliance, Capability Cost (Productivity) Cost (Productivity) Availability, Compliance Availability, Compliance Availability, Compliance Availability, Compliance Availability, Cost, Compliance Availability, Cost, Compliance Availability, Compliance
NA
NA
Work backlog (man weeks)
Total estimated manhours for all outstanding work orders Average age of equipment
Actual available hours to schedule each week Average useful life of equipment
To target. Say, Month about 4 man weeks To target. Year Stable or trend down
33
Lag
NA
NA
Equipment obsolescence ratio Cost of replacing obsolete items X Total cost of maintenance 100%
15 to 20
IND 2
Quarter/ Year
Lead
NA
NA
Plant renovation rate
35
Lag
NA
NA
Total cost of maintenance materials X Total cost of direct labour Materials/Labour ratio 100% Total internal direct man-hours worked X 100% Cumulative response time of all Emergency priority service calls Cumulative response time to all Ugent priority service calls Number of service calls within the target response time Total internal direct man-hours available Total number of Emergency priority service calls
To target
Month
Trend up
Month
36
Lead
NA
NA Quality , Deliver y, Quality , Deliver y, Quality , Deliver y, NA
Manpower utilisation Response time Emergency service calls Response time Urgent service calls
37
Lead
Lag
Trend down or Month stable
38
Lead
Lag
Total number of Urgent priority service Trend down or Month calls stable Total number of service calls Trend up or stable Month
39
Lead
Lag
Service level Fix/Make-Safe time Emergency priority service calls Rework rate
40
Lead
NA
Cumulative Fix/Make-Safe repair time Total number of Emergency priority of all Emergency priority service calls service calls Number of rework jobs X 100% Total number of jobs
Trend down or Month stable Trend down Month
41
Lead
NA
NA
42
Lag
Quality , Lead/Lag Deliver y NA NA
AS DEFINED Satisfaction Index Total number of work orders registered
AS DEFINED
Trend up
Month
None
43
Lead
Work-order volume
Trend down or stable
Month
44
Lead
Availability, Compliance Availability, Compliance Availability, Cost, Compliance Availability, Cost, Compliance, Capability Availability, Cost, Compliance Availability versus Cost Availability versus Cost
NA
NA
Work-order backlog
Total number of outstanding work orders
None
Stable
Month
45
Lead
NA
NA Quality , Deliver y, NA
Total number of work orders Work-order completion completed during the period rate Number of unexpected equipment failures resulting in downtime
None
Stable
Month
None
Trend down
Month
46
Lag
Lag
Plant failure rate
47
Lead
NA
Continuous improvement trend
Number of man-hours on continuous None improvenment activity
To target
Month
48
Lag
NA
NA
Internal direct man-hour trend
Total direct man-hours worked
None
Trend down
Month
Total cost of contractors
None
To target
Quarter
49
Lag
Lag
Cost
Contractor cost trend Total value of parts inventory None Trend down Quarter
50
Lag
Lag
Cost
Inventory trend
Indicators can check the same parameter from different perspectives
Leading Indicators of Maintenance Performance Engineering Manager's perspective
2009 Shire Systems Ltd Notes: 1. These indicators have been selected from the list on the Maintenance Indicator tab of this Workbook 2. To gain further information on the special nature of lagging and leading indicators of performance, view the Shire slideshow 'Lean Maintenance' 3. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators' Engineering Manager Role Perspective
ID Lead or Lag Tactical Goal Availability versus Cost Lead or Lag Lead Strategic Goal Total contractor Contractor cost ratio cost X 100% Total cost of maintenance materials
Business Manager Role Perspective
Indicator's Typical Name
Ratio Numerator
Ratio Denominator
Indicator Typical Target Value
Indicator Typical Reporting Period Month/ Quarter
Comment
(Any BSI designations refer to BSI 15341)
Lead
Cost
Total Maintenance Optimise Cost Average inventory Trend up value of maintenance materials Total Maintenance Trend down Cost
BSI E10
Year/ Quarter
BSI E12
Lead
Availability versus Cost
Lead
Cost
Stores turnover
Lead
Availability, Cost
Lead
Delivery, Cost
Shutdown ratio
Maintenance shutdown cost X 100%
Year
BSI E20
12
Lead
Availability, Cost, Compliance, Capability
NA
NA
Number of systems covered by a critical Risk Analysis ratio analysis X 100%
Total number of systems
10 to 15
Month/Quarter
BSI T18
13
Lead
Availability, Cost, Compliance
NA
NA
Planning ratio
Man-hours used for planning in a systematic maintenance planning process X 100%
Total internal maintenance personnel manhours
5 to 10
Month
BSI T19
14
Lead
Availability, Cost, Compliance
NA
NA
Number of assets in the condition Condition monitoring monitoring coverage program X100% ratio
Total number of candidate items for condition monitoring
20 Trend up
Month/ Quarter
See: Conditionbased maintenance ratio BSI O19
16
Lead
Availability, Cost, Compliance
Lead
Quality, Delivery, Cycle, Cost
Operator maintenance ratio
Production Total direct operator maintenance maintenance man- personnel manhours X 100% hours
Trend up
Month
BSI O4
17
Lead
Cost
NA
NA
Planned & Scheduled Work ratio
Planned and Total maintenance Trend up scheduled man-hours maintenance man- available hours X 100%
Month
BSI O5
18
Lead
Availability, Cost, Compliance, Capability
NA
NA
Continuous improvement ratio
Man-hours for continuous improvement X 100%
Total maintenance 5 to 10 personnel manhours Minimise
Month
BSI O8
19
Lead
Cost versus Availability
Lead
Quality, Delivery, Cycle Time versus Cost
Shift cover ratio
Direct Total direct maintenance maintenance personnel on shift personnel X 100% Number of internal Multiskilled maintenance personnel X 100%
Quarter/ Year
BSI O10
20
Lead
Availability, Cost
Lead
Delivery, Cycle Time, Cost
Number of internal Maximise maintenance personnel
Month/ Quarter
Multiskilled ratio
BSI O15. First Fix capability, especially on shift
21
Lead
Availability, Cost, Compliance
NA
NA
Corrective maintenance ratio
Corrective Total maintenance Trend down maintenance man- man-hours hours X 100%
Month
BSI O16
22
Lead
Availability, Cost, Compliance
NA
NA
Emergency maintenace manhour ratio
Immediate Total maintenance Trend down, Corrective man-hours < 10 maintenance manhours X 100%
Month
BSI O17
23
Lead
Availability, Cost, Compliance
NA
NA
Emergency maintenace work order ratio
Number of Total number or Immediate maintenace workCorrective orders completed maintenance workorderscompleted X 100%
Trend down, < 10
Month
24
Lead
Availability, Cost, Compliance
NA
NA
PM Routine Incidence
Number of major assets/systems with PM routines
Total number of major assets/systems
Target 100%
Quarter
25
Lead
Availability, Cost, Compliance
NA
NA
Preventive maintenace ratio
Preventive Total maintenance Trend up maintenance man- man-hours hours X 100%
Month
BSI O18
26
Lead
Availability, Cost, Compliance
NA
NA
PM performance
Number of PM Number of PM jobs completed X jobs scheduled 100%
Target 100
Month
27
Lead
Availability, Cost, Compliance
NA
NA
Condition-based maintenance ratio
Condition based Total maintenance Trend up maintenance man- man-hours hours X 100%
Month
BSI O19
28
Lead
Availability, Cost, Compliance
NA
NA
Schedule compliance
Number of work Total number of orders performed scheduled work as scheduled X orders 100%
Trend up, target 100%
Month
BSI O22
29
Lead
Availability, Cost, Compliance
NA
NA
Training ratio
Number of Total internal 3 to 5 maintenance maintenance maninternal personnel hours man-hours for training X 100%
Month/Quarter
BSI O23
30
Lead
Availability, Cost, Compliance
NA
NA
CMMS usage ratio
Number of internal direct maintenance people using software X 100%
Number of internal Target 100 direct maintenance personnel
Quarter/ Year
BSI O24
31
Lead
Availability, Compliance
NA
NA
Backlog age
Number of approved work orders over 3 months old
Total number of incomplete work orders
Stable
Month
32
Lead
Availability, Compliance
NA
NA
Work backlog (man weeks)
To target. Say, Month Total estimated Actual available manhours for all hours to schedule about 4 man weeks outstanding work each week orders
34
Lead
Availability, Cost, Compliance, Capability
NA
NA
Cost of replacing Total cost of obsolete items X maintenance Plant renovation rate 100% Total internal direct man-hours Manpower utilisation worked X 100% Cumulative response time of Response time Emergency service all Emergency priority service calls calls Total internal direct man-hours available
15 to 20
Quarter/ Year
Trend up
Month
36
Lead
Cost (Productivity)
NA
NA
37
Lead
Availability, Compliance
Lag
Quality, Delivery, Cycle, Cost
Total number of Trend down Emergency priority or stable service calls
Month
38
Lead
Availability, Compliance
Lag
Quality, Delivery, Cycle, Cost
Cumulative response time to Response time all Ugent priority Urgent service calls service calls
Total number of Urgent priority service calls
Trend down or stable
Month
39
Lead
Availability, Compliance
Lag
Quality, Delivery, Cycle, Cost
Service level
Number of service calls within the target response time
Total number of service calls
Trend up or stable
Month
40
Lead
Availability, Compliance
NA
NA
Cumulative Fix/Make-Safe Fix/Make-Safe time - repair time of all Emergency priority Emergency priority service service calls calls
Total number of Trend down Emergency priority or stable service calls
Month
41
Lead
Availability, Cost, Compliance
Number of rework Total number of jobs X 100% jobs NA NA Rework rate
Trend down
Month
43
Lead
Availability, Compliance
NA
NA
Total number of work orders Work-order volume registered
None
Trend down or stable
Month
44
Lead
Availability, Compliance
NA
NA
Total number of None outstanding work Work-order backlog orders Total number of None work orders completed during the period None
Stable
Month
Stable
Month
45
Lead
Availability, Compliance
NA
NA
Work-order completion rate
47
Lead
Availability, Cost, Compliance, Capability
NA
NA
Number of manhours on Continuous continuous improvement trend improvenment activity
To target
Month
Data requirements to calculate and report the BSI KPIs
2009 Shire Systems Ltd
To enable the reporting of performance, input data must be compatible. The following attributes of maintenace works must be recorded:
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) Training Planning Continuous improvement Routine Modification (changing the required function of an item) Project Priority 1 (respond immediately) Others Environmental damage Potential environmental damage Injury to persons Potential injury to persons Up times must be logged Down - failure (breakdown) Down - preventive maintenance Down - predetermined maintenance Down - condition based maintenance Down - Shutdown (planned outage) Down - other
Work Priority
Failure consequence
Plant up/down state during maintenace
System/Asset
Analysed Not analysed Internal Contractors Mechanical Electrical Instrumentation Multiskilled Production operator (Note: sum of all internal tradespersons can be assumed to be the direct internal personnel)
Personnel resource
Trades/Employee Group
Use of CMMS Complement
Number of direct internal maintenance people using the CMMS for more than 5% of their working time Total maintenance personnel (direct + indirect) Total number of employees (in the enterprise) List all maintenance staff in system, divided between direct and indirect
Other Maintenance KPIs & Metrics
Area/Group Level ID Indicator's Typical Name
Turmover ratio
2009 Shire Systems Ltd
Typical Target Value Typical Reporting Period Year 96
Numerator
Total cost of maintenance X100%
Denominator
Net sales turnover
Applicable Sectors
Comment
Plant availability
Hours the equipment was available to run Total hours in the reporting time period at capacity X 100% Total regular manhours of indirect maintenance personnel during period
Total overtime manhours worked by Overtime rate - indirect indirect maintenance personnel during internal personnel period X 100% Emergency job rate Condition monitoring coverage Thermography survey Steam trap survey Age of backlog workorders PM performance Overdue PM Work backlog (man weeks) Work-order volume Total number of outstanding work orders Work-order backlog Number of defective steam traps found X 100% Number of approved work orders over 3 months old Number of PM jobs completed X 100% Total emergency jobs worked X 100% Number of assets in the condition monitoring program X100% Number of faults found X100%
<2
Month
Total jobs worked Total number of candidate items for condition monitoring Number of devices surveyed 20
Month Quarter/ Year
<3
Quarter/ Month
Number of steam traps surveyed
< 10
Quarter/ Month Month
Number of PM jobs scheduled
Month Month
Number of overdue PM work orders at the None end of the period Total estimated manhours for all outstanding work orders Total number of work orders registered Actual available hours to schedule each week None None
~4 man weeks
Month
Month Month
Total number of work orders closed during None Work-order completion the period rate
Month
Man-hour estimation accuracy Cost estimation accuracy Volume of estimated work Plant renovation rate Equipment obsolescence ratio Stores issue service level Material ratio
Total estimated man-hours for completed work orders X 100% Total actual cost of work X 100%
Total actual man-hours for completed work orders Total estimated cost of work
Month
within 10 Quarter
Total cost of planned and estimated jobs X 10% Cost of replacing obsolete items X 100% Average age of equipment
Total cost of all jobs
Quarter/ Month
Total cost of maintenance Average useful life of equipment
15 to 20
Year Year
Number of material requisitions met from stock Total cost of maintenance materials
Total number of material requisitions
Month
Total cost of maintenance Total cost of direct labour
Month Month
Total cost of maintenance materials X Labour/materials ratio 100%
Plant failure rate
Number of unexpected equipment failures None resulting in downtime Total number of stoppages due to failure Loading time
Month
Month
Failure frequency Failure severity rate Emergency maintenance rate PM achievement Modifications trend Number of modifications completed None None Month Month Total stoppage time due to failure X 100% Loading time Number of emergency maintenance jobs X 100% PM tasks completed X 100% Total number of preventive maintenance + emergency maintenance jobs PM tasks planned 0.15 Month
Month
Number of modification proposals Modifications proposed registered trend
Total direct man-hours worked Internal direct man-hour trend Total cost of contractors Contractor cost trend Total value of parts inventories Inventory trend Manpower utilisation Total internal direct man-hours worked X 100% Total man-hours worked on shift X 100% Shiftwork incidence Cumulative response time of all Priority 1 Response time - Priority service calls 1 service calls Cumulative response time to all Priority 2 Response time - Priority service calls 2 services calls Number of service calls within the target Response performance response time Fix/Make Safe time Priority 1 Rework rate AS DEFINED Satisfaction Index Cumulative Fix/Make Safe repair time of all Priority 1 service calls Number of rework jobs X 100%
None
Month
None
Quarter
None Total internal direct man-hours available Total man-hours worked
Quarter Quarter Quarter
Total number of Priority 1 service calls
Month
Total number of Priority 2 service calls
Month
Total number of service calls
Month
Total number of Priority 1 service calls
Month
Total number of jobs AS DEFINED
Month
