Maintenance Performance
Module Objectives
Understand Key Measures For
Maintenance Performance (MP)
Learn how to use these MP
Learn about Techniques for Continuous
Improvement
Understand the elements of
maintenance benchmarking
Duffuaa 1
Measures Of Performance
Input Measures Primarily Cost Measures
Output measures
Within The System Measures
Maintenance Indices
Duffuaa 2
Input Measures
Input Measures are Mostly Related To Cost
Labor : Cost of trades, semi-skilled etc
Materials
Contracts
Shop Service
Equipment Rentals
Maintenance Overhead
Company Overhead
3
Output Measures
Availability : Measure of Uptime
A = S-d/S * 100% , Where
A = availability
S = scheduled production time
d = downtime in days
Duffuaa 4
Output Measures
Reliability : Mean-time-between-failure
MTBF = S-d/f , f is number of failures
Mean Time To Repair: Measure of Duration
of Repair
• MTTR = d/f
Utilization = Scheduled Time/C T
CT = Calendar Time
Duffuaa 5
Output Measures
Process Rate (PR) : Measure of the
Equipment Cycle Time in The Process
• PR = Ideal Cycle Time/Actual Cycle time
Quality Rate (QR) : Measure of equipment
Precision
• Total Produced - Rejected/Downgrades/ Total
Overall equipment Effectiveness
• OEE = A* PR *QR
Duffuaa 6
Example
Suppose We have An Operation Scheduled
To Operate For 31 Days. It has three
failures. The Failures Duration Are For 2, 1
And 3 Days. Compute Availability,
Percentage Down Time ( PDT) , MTBF and
MTTR
Duffuaa 7
Solution
A = (31-6)/31 * 100 = 80.6%
PDT = 100 - 80.6 = 19.4
MTBF = (31 - 6)/3 = 8.33
MTTR = Down Time From Failures/Number of Failure
= 6/3 = 2 days
Duffuaa 8
Problem
A cement kiln has a requirement to operate
300 days per year, producing at a rate of
1200 tones per 24 hour day. Over the year
its performance has been as follows.
Scheduled operation time 300 days,
Number of Breakdowns are 6,
Delays for Breakdowns accounted for 180 hours
Preventive Maintenance time is 80 hours
Duffuaa 9
Problem
Shutdown due to lack of feed lasted for 120 hours
Process Slowdowns is for 60 hours at 80% rate
Wet Feed Slowdowns is 40 hours at 60% rate
Total rejected production is 2000 tones
Second quality production is 3000 tones at 50%
value
Compute: Utilization, Availability, Process
rate, quality rate, OEE, productive capacity
Duffuaa 10
Measures Within The System
Work Distribution : Time Spent in each
work category
Delays : Time spent waiting for instructions
parts, travel,breaks, Start and Quits
Compliance : Measures to Track
Compliance with various plans, such as
PM, Shutdown schedules etc.
Duffuaa 11
Measures Within The System
Backlog : Amount of Work Planned but not
Completed by Plant, Area, Craft, etc
Failure Analysis: Tracks improvement
analysis, such Number of New PM
Routines, Number of Root Cause Analysis
of Breakdowns Undertaken.
Duffuaa 12
Maintenance Indices For
Administration
Subcontracted Hours Per Month Calculated
as % of Total Subcontracted Hours Worked
from Total Hours Worked
Overtime Hours Per month Calculated as
%from Total Hours Worked
Work Activity Calculated by the ratio of
Standard Hours Earned To Total Clock
Time
Duffuaa 13
Maintenance Indices For
Administration
Current Backlog Given As :
Work Scheduled Ready To Release/One Crew week in Man-hour
Work Productivity Per Month Calculated
As: Standard Hours/ Total Hours Worked * 100
Percentage Work Orders Planned and schedules
monthly from of Total Hours Worked
Percentage Scheduled Hours Versus Hours worked
Duffuaa 14
Maintenance effectiveness
Availability
Quality
Number of failures in The system
Equipment Down Time
Emergency Man-Hours As A percentage From
Total Hours
Percentage of Unscheduled Maintenance From
Total
Duffuaa 15
Maintenance effectiveness
Evaluation of Predictive Maintenance
Which Ones Can You adopt In SCECO.
Duffuaa 16
Cost Measures
Cost Per Unit: Total Maintenance cost Per
Kilo-Watt Hour
Supervision Cost As A Percentage Of Total
Cost Of Maintenance
Cost of Maintenance Hour in SR.
• Total Cost of Maintenance/Total Man-hours
Duffuaa 17
Cost Measures
PM Cost As A Percentage Of Breakdown
Cost
Inventory Turn rate (Rate) : Annual
Consumption Cost/ Average Investment Inv
Cost Of Spare part and material to
Maintenance Cost
Duffuaa 18
Performance analysis
Make These Measures Part Of Monthly
Report
Examine trend
Benchmark With Other Companies.
Duffuaa 19
Benchmarking
Benchmarking is A continuous
Improvement Methodology. It Examines
The Process and Metrics to Achieve These
Metrics. It Is Defined As:
The Search Of Industry Best Practices that
Lead to Superior Performance
Duffuaa 20
Types Of Benchmarking
It Is Divided In Three types :
Internal : This Deals With Comparison
among Similar Operations Within Same
Organization
Competitive : Comparison with The Best Of
The Direct Competitors
Duffuaa 21
Types Of Benchmarking
Functional : Comparisons With Similar
Processes In Same Functions Outside
One’s Industry
Generic : Comparison of Work Processes To
Others Who Have Innovative Exemplar
Work Processes
Duffuaa 22
The benchmarking Process-- 10
steps
Identify What To Benchmark
Identify Whom To benchmark
Plan And Conduct The investigation
Determine The Current Performance Gap
Project Future Performance Levels
Duffuaa 23
The benchmarking Process-- 10
steps
Communicate Benchmarking Findings and
Gain Acceptance
Revise Performance Goals
Develop Action Plans
Implement Specific Actions And Monitor
Progress
Recalibrate The Benchmarks
Duffuaa 24
What To Benchmark In
Maintenance
• .long range planning and improvement
initiatives
• .organization and manpower planning
• .work planning, scheduling and control
• .purchasing, stores, and inventory
control
• .preventive and predictive maintenance
Duffuaa 25
What To Benchmark In
Maintenance
• .performance measures and statistics
• .information management and systems
• .reliability engineering
• .maintenance/production interface and
communication
• .management and administrative
processes
Duffuaa 26
Activity based Costing (ABC)
This Is An Approach That Is Process Based
For Determining Accurate Cost For
Processes. It Examines The Process By
Activities Are Delivered
Duffuaa 27
Steps Of Activity Based Costing
(ABC)
• Determine the key activities.
• Determine the activity cost (labor,
materials, services, overheads, etc.)
and performance (cost/unit, time
quality, etc.)
Duffuaa 28
ABC Steps Continued
• Determine the cost driver or output of the activity.
• Trace this activity cost to the cost objectives;.
• Evaluate the cost-effectiveness and efficiency by matching
the activity cost to the process objectives
Duffuaa 29
