Maintenance Performance Metrics: Using Data to Drive Decisions

Maintenance Performance Metrics
… Using Data to Drive Decisions
Jim McCaherty
Mining Forum - Peoria
September 23 - 28, 2007
Why do we measure?
Management without metrics is “management” by intuition.
2
Why do we measure?
ANSWER: Metrics help us make sense of our
situation; we become smarter and gain
some degree of control over the outcome.
OBSERVATION
Mining equipment management
spends more time reporting
performance than improving
performance.
3
*
Reports serve three primary purposes:
 to provide basic performance information to top management,
 to identify problems or needed action, and
 to set priorities for the problem management (continuous

improvement) process.
* Only the latter two provide information that directly helps to improve the operation.
4
Objective
Define a process using data that is commonly
available at most sites to develop quantifiable
measures to assess site performance and
identify weak areas, poor practices and other
opportunities for improvement. Use the
process as a “Management Tool” to prioritize
and attack the key issues affecting
performance.
5
Why use Performance Metrics?
• ____________
To assign and fix blame.
• To assess, quantify and document “as is” performance

relative to internal targets and established benchmarks.
• To highlight shortcomings and opportunities for improvement

relative to design, application and maintenance.
• To establish priorities in the deployment of resources.
• etc.
6
PHILOSOPHY
Apply what you know to what you would like
to know!
7
What would you like to know?
… from a Maintenance perspective
Cost / Hour Cost / Ton Tons / Hour
Rebuild Costs Component Lives Production Availability
Application
% A/F Design
Repairs Quality  Pit Depth
 Haul Distance
 Grades
 …
Parts Application
Reuse
Maintenance Operation
Parts
 Op Skill
Price Repair Quality  P’Load
Mgmt.
 Bunching
others  Delays
 Blasting
 …
8
*
Availability:
 Used to measure performance and contributions of
Equipment Management team in support of the
mine’s production goals.
What would you like to know?

 How well is my Maintenance organization performing?
 If my performance is substandard,
• Why?
• What can I do to improve it?
9
Availability:
Variations (general forms):
Total Calendar Hours – all Downtime Hours
Physical Availability =
Total Calendar Hours
Total Calendar Hours – mechanical Downtime Hours

Mechanical Availability =
Total Calendar Hours – MARC Downtime Hours

Contractual Availability =
10
Availability:
Variations (general forms):
Scheduled Hours – all Downtime Hours
Physical Availability =
Scheduled Hours
Scheduled Hours – mechanical Downtime Hours

Mechanical Availability =
Scheduled Hours
Scheduled Hours – MARC Downtime Hours

Contractual Availability =
Scheduled Hours
What is the problem here?

11
*
What is the problem here?

Total Calendar Hours – Downtime Hours
Availabilitygeneral form =
Availability is driven by …..

 Repair Frequency
 Repair Duration
 Utilization
12
Identify Key Performance Indicators &
Establish Benchmarks:
Repair Frequency .… MTBS (Mean Time Between Shutdowns)
machine reliability
repair quality / maintenance effectiveness
Benchmark = 60 to 80 hours
13
MTBS (Mean Time Between Shutdowns)
 Defines the frequency of machine downtime events;

an indication of inherent machine reliability &
equipment management effectiveness.
Operating Hours
MTBS (hours) =
number of shutdowns in the period
14
machine reliability
Repair Duration .….. MTTR (Mean Time To Repair)
machine serviceability
repair timeliness / maintenance efficiency
15
MTTR (Mean Time To Repair)
 Defines the average duration of machine downtime

events; an indication of machine serviceability
& equipment management efficiency.
Total Downtime Hours

MTTR (hours) =
16
machine reliability
Repair Duration .….. MTTR (Mean Time To Repair)
machine serviceability
repair timeliness / maintenance efficiency

Utilization ………… Operated Hours / Available Hours
Results are determined by Operations
NOT Maintenance
17
Availability:
Operating Hours + Stand-By Hours
Availability general form =
Operating Hours + Stand-By Hours + Downtime Hours
Operating Hours
Availability Index =
Operating Hours + Downtime Hours
Operating Hrs / Shutdowns

Operating Hrs / Shutdowns + Downtime Hrs / Shutdowns
Availability Index (%) = (MTBS / (MTBS + MTTR))*100
18
Reliability &
Repair Effectiveness
MTBS
MTBS + MTTR
Serviceability &
Repair Efficiency
 Defines a “normalized” availability KPI by ignoring the effects

of utilization.
 Benchmark = 88 to 92%.
Availability Index is the Availability

“Management Tool”…
19
Availability Index & MTBS
100%
90%
80%
Availability Index - (%)
70%
Why MTBS?
60%
50%
40%
30%
20%
10%
0%
0 25 50 75 100 125 150 175 200
MTBS - (hours)
MTTR = 3 hrs MTTR = 4.5 hrs MTTR = 6 hrs MTTR = 7.5 hrs MTTR = 9 hrs MTTR = 12 hrs
20
Maintenance & Repair Management Scenario
First PCR Equipment
cycle Disposal
Machine Life Cycle

(Based on PCR)
PCR * X
Downtime Reasons Detection Routines

Unscheduled
Repairs Periodic Services Scheduled Repairs
PCR
(Major & Minor)
(Planned Component
Replacement)
• Vital to minimize / • Who’s in Control? • Fixed frequency • A planning window to • Frequency determined
Downtime Major prevent unscheduled keep condition of the by component life targets
Characteristics stops • Must be minimized • Well known routine machine at defined level & health
• Frequency; a function • Negative influence on • The foundation of • Frequency determined • Window used for
of MTBS MTBS, MTTR & efficient / effective by Planning restoring machine to
Availability maintenance mgmt. standard
• Frequency to be • Starting point of a

controlled new component life
cycle
Ability to build a MTBS, MTTR & Availability Ability to maintain the

Impact On preventive plan maintenance plan maintenance plan Costs ($)
21
Maintenance & Repair Management Scenario
PCR * X
…
Downtime Reasons Unscheduled PCR
Detection Routines Periodic Services Scheduled Repairs Planned Component
Repairs
(Major & Minor) Replacement
Maintenance Management Process
Preventive Maintenance Condition Monitoring Repair Management Component Management

First Line
Planning & Scheduling
Backlog Management Parts Management Training / HR

Support Processes
Performance Evaluation
Evaluation
Continuous Improvement
Correct / Improve
22
Why MTBS? First PCR
cycle
Equipment
Disposal
Machine Life Cycle

(Based on PCR)
PCR * X
…
PCR
Downtime Reasons Detection Unscheduled Periodic Scheduled Repairs (Planned
Routines Repairs Services (Major & Minor) Component
Replacement)
MTBF:
 Considers only Failures … Unscheduled Repairs (reliability element).
MTBnF:
 Considers non-Failures … quantifies our efforts in Failure avoidance
(influence reliability).
The Relationship: 1 / MTBS = 1 / MTBF + 1 / MTBnF

23
PHILOSOPHY
Apply what you know to what you would like
to know!
24
What do we know ?
Start Complete
CompleteRepair
Repair Repair
Labor Stop
Stop Scheduled
Equipment ID
Start Number
Repair
Equipment ID Number Labor Man-
Stop Man-
Code Service Meter Scheduled
StopHoursCode Reason Service
Comments Meter
(Date & (Date
Time)
(Date&&Time)
Time)
DurationHours Reason Comments Reading
(Date & Time) Duration Field
ReadingField/ /Shop
Shop
Equip. Start Repair Complete Repair Stop Labor Shop /

Code Reason Comments SMR Stop Scheduled
ID (Date / Time) (Date / Time) Duration Manhours Field?
HT001 4/1/03 12:00 AM 4/1/03 12:00 AM 0.00 0.00 1 comment Document SMR 16214.4 N/A N/A
HT001 4/3/03 7:06 PM 4/3/03 7:33 PM 0.44 0.00 162 Delays Waiting for Mechanic 16279.8 S No
HT001 4/3/03 7:33 PM 4/5/03 7:21 AM 35.80 35.80 100 Engine Low engine power 16279.8 S No
HT001 4/5/03 7:21 AM 4/6/03 9:25 PM 38.07 76.14 111 Cooling System Replace aftercooler gasket 16279.8 Yes S No
HT001 4/7/03 9:29 AM 4/7/03 11:10 PM 13.67 41.00 202 PM 2000 Hr PM 16291.6 Yes S Yes
Scope & Goals of Project

HT001 4/8/03 4:42 PM 4/8/03 6:02 PM 1.35 4.00 120 Tires & Rims Replace tire - position #3 16308.7 Yes S No
HT001 4/9/03 1:41 AM 4/9/03 1:52 AM 0.18 0.00 162 Delays Waiting for Mechanic 16316.2 S No
HT001 4/9/03 1:52 AM 4/9/03 2:17 AM 0.41 0.41 118 Suspension System L/F Suspension Noise 16316.2 S No
HT001 4/9/03 2:17 AM 4/9/03 6:24 AM 4.11 12.33 120 Tires & Rims Replace tire - positions #1 & 2 16316.2 Yes S No
HT001 4/9/03 9:00 PM 4/10/03 3:16 AM 6.27 6.27 100 Engine Low boost pressure 16330.2 Yes S No
HT001 4/10/03 5:02 AM 4/10/03 5:07 AM 0.08 0.00 162 Delays Waiting for Mechanic 16331.9 F No
HT001 4/10/03 5:07 AM 4/10/03 5:31 AM 0.40 0.40 128 Cab / Operator Station Repair L/H Door Lock 16331.9 Yes F No
HT001
HT001
HT001
HT001
4/10/03 6:21 AM
4/10/03 6:26 AM
4/14/03 3:28 PM
4/14/03 3:39 PM
 Small fleet of 793 OHT’s
4/10/03 6:26 AM
4/10/03 6:42 AM
4/14/03 3:39 PM
4/14/03 9:21 PM
0.08
0.27
0.19
5.69
0.00
0.27
0.00
5.69
162
128
162
100
Delays
Cab / Operator Station
Delays
Engine
Waiting for Mechanic
Repair L/H Door Lock
Engine oil leaks / Low boost pressure
16332.8
16332.8
16434.8
16434.8
Yes
Yes
F
F
S
S
No
No
No
No
HT001 4/14/03 11:01 PM 4/15/03 2:22 AM 3.34 3.34 100 Engine Low engine power 16436.4 Yes S No
HT001
HT001
HT001
HT001
4/15/03 2:55 AM
4/15/03 3:23 AM
4/15/03 4:48 AM
4/15/03 4:57 AM
 Availability Target = 88%
4/15/03 3:23 AM
4/15/03 4:11 AM
4/15/03 4:57 AM
4/15/03 5:57 AM
0.48
0.79
0.16
0.99
0.00
0.79
0.00
0.99
162
100
162
100
Delays
Engine
Delays
Air Intake & Exhaust System
Engine derate 30
Air cleaner plugged
16437.0
16437.0
16437.6
16437.6
Yes
Yes
F
F
F
F
No
No
No
No
HT001 4/15/03 7:35 AM 4/15/03 8:05 AM 0.51 0.51 120 Tires & Rims Tire Check - Pos. #3 16439.1 Yes F No
HT001 4/16/03 12:51 PM 4/16/03 12:56 PM 0.08 0.00 162 Delays Waiting for Mechanic 16467.2 F No
HT001 4/16/03 12:56 PM 4/16/03 1:25 PM 0.48 0.48 100 Engine Low engine oil level 16467.2 Yes F No
HT001 4/17/03 2:22 AM 4/17/03 9:29 AM 7.12 7.12 100 Engine Engine derate 31 16479.7 Yes S No
HT001 4/17/03 9:58 AM 4/17/03 1:09 PM 3.19 3.19 100 Engine Engine derate 31 16479.9 Yes S No
25
The process - STEP 1:
Evaluate Overall Fleet Performance
HT001 4/3/03 7:33 PM 4/5/03 7:21 AM 35.80 35.80 100 Engine Low engine power 16279.8 S No
HT001 4/8/03 4:42 PM 4/8/03 6:02 PM 1.35 4.00 120 Tires & Rims Replace tire - position #3 16308.7 Yes S No
HT001 4/9/03 1:52 AM 4/9/03 2:17 AM 0.41 0.41 118 Suspension System L/F Suspension Noise 16316.2 S No
HT001 4/9/03 2:17 AM 4/9/03 6:24 AM 4.11 12.33 120 Tires & Rims Replace tire - positions #1 & 2 16316.2 Yes S No
HT001 4/9/03 9:00 PM 4/10/03 3:16 AM 6.27 6.27 100 Engine Low boost pressure 16330.2 Yes S No
HT001 4/14/03 3:39 PM 4/14/03 9:21 PM 5.69 5.69 100 Engine Engine oil leaks / Low boost pressure 16434.8 Yes S No
HT001 4/14/03 11:01 PM 4/15/03 2:22 AM 3.34 3.34 100 Engine Low engine power 16436.4 Yes S No
HT001 4/15/03 3:23 AM 4/15/03 4:11 AM 0.79 0.79 100 Engine Engine derate 30 16437.0 Yes F No
HT001 4/15/03 4:57 AM 4/15/03 5:57 AM 0.99 0.99 100 Air Intake & Exhaust System Air cleaner plugged 16437.6 Yes F No
26
MTBS What do we need?
27
MTBS
Operating Hours
MTBS (hours) =
3415.77
MTBS (hours) = = 20.70 hours
165
28
MTTR What do we need?
29
MTTR
Downtime Hours
MTTR (hours) =
838.60
MTTR (hours) = = 5.08 hours
165
30
Availability Index
MTBS
MTBS + MTTR
20.70
Availability Index = = 80.29%
20.70 + 5.08
31
*
Analysis:
 Overall fleet performance is substandard …

Availability Index = 80.29%.
 MTTR is within acceptable limits (5.08 hours),
 MTBS is too low (20.70 hours).
STEP 2:
Analyze Overall Fleet Performance
32
*
Interpretation:
 Overall fleet performance is substandard …

Availability Index = 80.29%.
 MTTR is within acceptable limits (5.08 hours).
 MTBS is cause of low availability.
33
% Scheduled Downtime .…
 Defines the extent that Equipment
Management is in control of
the situation vs. reacting to it.
 Effectiveness of the Equipment
Management system.
 Benchmark = 80% of all DT is
planned & scheduled.
Scheduled Downtime Hours

% Scheduled Downtime =
34
% Scheduled What do we need?
35
% Scheduled
Scheduled Downtime Hours

% Scheduled Downtime =
168.10
% Scheduled Downtime = = 20.05%
838.60
 Low MTBS is result of unscheduled downtime.
STEP 3:
Develop an Action Plan
36
Recommendations / Action Plan:
 Evaluate / analyze individual machine performance.
 Evaluate / analyze fleet performance on a

component & system basis.
 Take steps to increase % Scheduled Downtime.
37
STEP 4:
Evaluate Individual Machine
Performance
38
*
Analysis / Interpretation:
 Truck No. HT002 is performing well below the

average of the rest of the fleet.
 Availability Index = 56.16%.
 54 shutdowns in one month (30 days).
39
 Use Pareto analysis (significant few / trivial many)

to identify key problem(s) affecting truck HT002.
 Bring HT002 up to standard to improve overall fleet
performance.
NOTE: Truck HT002 is dragging down the
overall fleet average (-4.85% ).
 Apply same approach to another machine.
40
Pareto Analysis – HT002
41
Pareto Analysis – HT002
42
43
44
STEP 5:
Analyze Truck HT002 Performance
45
 Chronic (repetitive) repairs performed on truck
HT002 due to engine and electrical system.
 Incorrect problem diagnosis and/or poor repair
execution (“redo”) are leading to excessive
number of repetitive problems.
NOTE: 85.5% of downtime & 77.8% of shutdowns
on truck HT002 are due to engine and electrical
system.
 Eliminating “redo” on HT002 will increase fleet MTBS
by 41% and reduce fleet downtime (increase
STEP 6:
availability) by 31%.
Develop an Action Plan

46
 “Drill down” into engine & electrical system
problems to determine root cause(s) of downtime in
those areas.
 Train on engine & electrical system diagnostics
/troubleshooting and repair execution.
 Consider developing “Specialists” in these two
critical areas.
STEP 7:
Evaluate Component / System
Performance
47
Top Problem Summary .…
 Enables Equipment Management
to identify the most significant issues
and focus its resources on their
containment & resolution.
 “Rule of Thumb”: Apply Pareto
analysis; information must be
quantified and compared against
historical performance and / or
established references.
 Target: All downtime is documented by
cause and in terms of frequency,
duration and cost of each repair.
48
Top Problem Summary
49
Top Problem Summary
50
Top Problem Summary
To Calculate Impact on Availability:
Total Downtime
= Total Downtime
(system / component)
X (1 - Availability Index)
(all causes)
EXAMPLE:
Total Downtime
= Total Downtime
(Engine)
X (1 - Availability Index)
(all causes)
268.97 hours
= 838.60 hours
X (1 -.8029)
= 6.32% (impact of engines on fleet availability)
51
Top Problem Summary
STEP 8:
Analyze Component / System
Performance
52
Top Problem Summary
53
Top Problem Summary
Opportunity to Improve:
= Availability actual – Availability reference
EXAMPLE:
Opportunity to Improve = 6.32% – 1.61% = 4.71%
54
• Pareto applies … Top four issues (20%) account for 73.5% of all
downtime (14.5% lost availability).
• Opportunity to improve > 12%.
55
• Time invested in PM is low (70% of reference).

• Inadequate PM time is likely contributing to very low fleet MTBS.
• NOTE: MTBSafter PM (PM quality / effectiveness) is low (30 hours).
56
• Delays are a chronic problem (100 events) but the impact on

availability is minimal (0.65%).
• Substantial number of delays is due to low percentage of scheduled
downtime.
57
• “Drill down” into engine, electrical, cooling &
steering system problems to determine root
cause(s) of downtime in those areas.
• Review PM practices … time invested in PM is

low & PM effectiveness is substandard. Consider:
 Random post-PM audits,
 Reducing PM interval to 250 hours,
 Revising PM checklists to emphasize top issues.
• Minimize or eliminate delays through improved

Condition Monitoring (defect detection) …
increase MTBS & % Scheduled Downtime.
58
Observations / Recommendations (general):
• Highly utilized fleet performing poorly.
• Maintenance organization is extremely reactive; operation is out of
control.
• Percentage of scheduled downtime is very low (20% by hours /
4.2% by event.
• PM and Condition Monitoring functions are substandard.
• Information management is ineffective … not learning from failures.
• Invest in efforts to put management in control of the operation.
• Reinforce / emphasize PM & Condition Monitoring practices.
• Learn from failures … “Past performance is frequently a valid
predictor of future behavior” !
59
Which method is your organization using?

HT001 4/3/03 7:06 PMStart 4/3/03
Equip. Repair7:33 PM
Complete 0.44Repair 0.00
Stop 162 Labor Delays Waiting for Mechanic 16279.8 S No /
Shop
HT001 4/3/03 ID
7:33 PM(Date 4/5/03 CodeEngine Reason Low engine powerComments 16279.8 SMR S Stop No Scheduled
/ Time)7:21 AM(Date / 35.80
Time) 35.80
Duration 100
Manhours Field?
HT001 4/3/03 7:06 PMStart 4/3/03 7:33 PM 0.44
Repair 1200.00
Stop 162 Delays Waiting for Mechanic 16279.8 S No /
HT001 4/8/03 4:42 PM Equip.
4/8/03 6:02 PMRepair 1.35Complete4.00 Labor
Tires & RimsCode Replace
Reason tire - position #3 16308.7 Yes S No Shop
HT001 4/3/03 ID 7:33 PM(Date 4/5/03 7:21 AM 35.80 35.80 100 Engine Low engine powerComments 16279.8 SMR S Stop No Scheduled
HT001 4/9/03 1:41 AM 4/9/03 1:52 AM/ Time) 0.18 (Date /0.00 Time) 162 Duration Manhours
Delays Waiting for Mechanic 16316.2 S No Field?
HT001 4/9/03 1:52 AM HT0014/9/03 2:17 AM
4/1/03 12:00 AM0.41 4/1/03 12:00
0.41 AM 118 0.00 Suspension 0.00 System 1 L/F Suspension Noise
comment 16316.2 SMR
Document S No
16214.4 N/A N/A
HT001 4/9/03 2:17 AM HT0014/9/03 6:24 AM7:06 PM4.11
4/3/03 4/3/0312.33
7:33 PM 120 0.44 Tires
0.00& Rims 162Labor Replace tire - positions #1 & 2 Waiting
Delays 16316.2 Yes
for Mechanic S No
16279.8 S No /
HT001 4/8/03 4:42 PM Equip. Start
4/8/03 6:02 PMRepair 1.35Complete Repair 120
4.00 Stop Tires & RimsCode Replace
Reason tire - position #3 16308.7 Yes S No Shop
HT001 4/9/03 8:48 PM HT0014/9/03 9:00 PMID
4/3/03 0.20 4/5/03
7:33 PM(Date 0.00 AM 162 35.80
7:21 Delays Manhours
35.80 100 Waiting for Mechanic
Engine engine powerComments
16330.2
Low S No
16279.8 SMR S Stop No Scheduled
HT001 4/9/03 1:41 AM 4/9/03 1:52 AM/ Time) 0.18 (Date /0.00Time) 162Duration Delays Waiting for Mechanic 16316.2 S No Field?
HT001 4/9/03 9:00 PM HT001
4/10/03 3:16 AM
4/5/03 7:21 AM6.27 4/6/03 6.279:25 PM 100 38.07 Engine 111
76.14 LowSystem
Cooling boost pressure 16330.2
Replace Yesgasket S
aftercooler No Yes
16279.8 S No
HT001 4/9/03 1:52 AM HT001 4/9/03 2:17 AM
4/1/03 12:00 AM0.41 4/1/03 12:00
0.41 AM 118 0.00 Suspension 0.00 System 1 L/F Suspension Noise
comment 16316.2 SMR
Document S No
16214.4 N/A N/A
HT001 4/10/03 5:02 AM HT001
4/10/03 5:07 AM
4/7/03 9:29 AM0.08 4/7/03 11:10
0.00 PM 162 13.67 Delays 202
41.00 Waiting
PM for Mechanic 16331.9
2000 Hr PM F No Yes
16291.6 S Yes
HT001 4/9/03 2:17 AM HT001 4/9/03 6:24 AM7:06 PM4.11 4/3/0312.33
4/3/03 7:33 PM 120 0.44 Tires
0.00& Rims 162 Replace tire - pos itions #1 & 2 Waiting
Delays 16316.2 Yes
for Mechanic S No
16279.8 S No
HT001 4/10/03 5:07 AM HT001
4/10/03 5:31 AM
4/8/03 4:42 PM0.40 4/8/03 0.406:02 PM 128 1.35 Cab / Operator
4.00 Station120 Repair
Tires & RimsL/H Door Lock Replace 16331.9 Yes #3 F
tire - position No Yes
16308.7 S No
HT001 4/9/03 8:48 PM HT001 4/9/03 9:00 PM7:33 PM0.20 4/5/03 7:21
4/3/03 0.00 AM 162 35.80 Delays 100
35.80 Waiting for Mechanic
Engine Low16330.2
engine power S No
16279.8 S No
HT001 4/10/03 6:21 AM HT001
4/10/03 6:26 AM
4/9/03 1:41 AM0.08 4/9/03 1:520.00 AM 162 0.18 Delays 162
Delays 16332.8
Waiting for Mechanic F No
16316.2 S No
HT001 4/9/03 9:00 PM HT001 4/10/03 3:16 AM
4/5/03 7:21 AM6.27 4/6/03 6.27
9:25 PM 100 38.07 Engine 111
76.14 CoolingLowSystem
boost pressure Replace16330.2 Yesgasket S
aftercooler No Yes
16279.8 S No
HT001 4/10/03 6:26 AM HT001
4/10/03 6:42 AM
4/9/03 1:52 AM0.27 4/9/03 2:170.27 AM 128 0.41 Cab / Operator
0.41 Station118 RepairSystem
Suspension L/H Door Lock 16332.8 Yes
L/F Suspension Noise F No
16316.2 S No
HT001 4/10/03 5:02 AM HT001 4/10/03 5:07 AM
4/7/03 9:29 AM0.08 4/7/03 11:10
0.00 PM 162 13.67 Delays 202
41.00 Waiting
PM for Mechanic 16331.9
2000 Hr PM F No Yes
16291.6 S Yes
HT001 4/14/03 3:28 PM HT0014/14/03 4/9/03
3:39 PM2:17 AM0.19 4/9/03 6:24 0.00 AM 162 4.11 Delays 120
12.33 Waiting
Tires & Rimsfor Mechanic Replace16434.8 tire - positions #1 & 2S No Yes
16316.2 S No
HT001 4/10/03 5:07 AM HT001 4/10/03 5:31 AM
4/8/03 4:42 PM0.40 4/8/03 0.40
6:02 PM 128 1.35 Cab / Operator 4.00 Station
120 Repair
Tires & RimsL/H Door Lock Replace 16331.9 Yes #3 F
tire - position No Yes
16308.7 S No
HT001 4/14/03 3:39 PM HT0014/14/03 9:21 PM8:48 PM5.69 4/9/03 5.69
4/9/03 9:00 PM 100 0.20 Engine 162
0.00 Engine oil leaks / Low boost pressure
Delays 16434.8
Waiting Yes
for Mechanic S No
16330.2 S No
HT001 4/10/03 6:21 AM HT001 4/10/03 6:26 AM
4/9/03 1:41 AM0.08 4/9/03 1:52
0.00 AM 162 0.18 Delays 162
Delays 16332.8
16316.2 S No
HT001 4/14/03 10:54 PM HT001
4/14/03 11:01
4/9/03PM9:00 PM0.12 4/10/030.003:16 AM 162 6.27 Delays 100
Engine Low16436.4
boost pressure S No Yes
16330.2 S No
HT001 4/10/03 6:26 AM HT001 4/10/03 6:42 AM
4/9/03 1:52 AM0.27 4/9/03 2:17
0.27 AM 128 0.41 Cab / Operator 0.41 Station
118 RepairSystem
Suspension L/H Door Lock 16332.8 Yes
L/F Suspension Noise F No
16316.2 S No
HT001 4/14/03 11:01 PM HT001
4/15/03 4/10/03
2:22 AM5:02 AM3.34 4/10/033.34 5:07 AM 100 0.08 Engine 162
0.00 Low engine power
Delays 16436.4
Waiting Yes
for Mechanic S No
16331.9 F No
HT001 4/14/03 3:28 PM HT001 4/14/03 4/9/03
3:39 PM2:17 AM0.19 4/9/03 6:24
0.00 AM 162 4.11 Delays 120
12.33 Waiting
Tires & Rimsfor Mechanic Replace16434.8 tire - positions #1 & 2S No Yes
16316.2 S No
HT001 4/15/03 2:55 AM HT001
4/15/03 4/10/03
3:23 AM5:07 AM0.48 4/10/030.00 5:31 AM 162 0.40 Delays 128
0.40 WaitingStation
Cab / Operator for Mechanic 16437.0
Repair L/H Door Lock F No Yes
16331.9 F No
HT001 4/14/03 3:39 PM HT001 4/14/03 9:21 PM8:48 PM5.69 4/9/03 5.69
4/9/03 9:00 PM 100 0.20 Engine 162
0.00 Engine oil leaks / Low boost pressure
Delays 16434.8
Waiting Yes
for Mechanic S No
16330.2 S No
HT001 4/15/03 3:23 AM HT001
4/15/03 4/10/03
4:11 AM6:21 AM0.79 4/10/030.79 6:26 AM 100 0.08 Engine
0.00 162 Engine
Delays derate 30 16437.0 Yes
16332.8 F No
HT001 4/14/03 10:54 PM HT001 4/14/03 11:01
4/9/03PM9:00 PM0.12 4/10/030.00
3:16 AM 162 6.27 Delays 100
Engine Low 16436.4
boost pressure S No Yes
16330.2 S No
HT001 4/15/03 4:48 AM HT001
4/15/03 4/10/03
4:57 AM6:26 AM0.16 4/10/030.00 6:42 AM 162 0.27 Delays 128
0.27 WaitingStation
16332.8 F No
HT001 4/14/03 11:01 PM HT001 4/15/03 4/10/03
2:22 AM5:02 AM3.34 4/10/033.34
5:07 AM 100 0.08 Engine 162
0.00 Low engine power
Delays 16436.4
Waiting Yes
for Mechanic S No
16331.9 F No
HT001 4/15/03 4:57 AM HT001
4/15/03 4/14/03
5:57 AM3:28 PM0.99 4/14/030.99 3:39 PM 100 0.19 Air Intake 0.00
& Exhaust 162
System Air cleaner plugged
Delays 16437.6
Waiting Yes
for Mechanic F No
16434.8 S No
HT001 4/15/03 2:55 AM HT001 4/15/03 4/10/03
3:23 AM5:07 AM0.48 4/10/030.00
5:31 AM 162 0.40 Delays 128
0.40 WaitingStation
16331.9 F No
HT001 4/15/03 7:35 AM HT001
4/15/03 4/14/03
8:05 AM3:39 PM0.51 4/14/030.51 9:21 PM 120 5.69 Tires
5.69& Rims 100 Tire Check - Pos. #3Engine oil leaks
Engine 16439.1
/ Low Yes F
boost pressure No Yes
16434.8 S No
HT001 4/15/03 3:23 AM HT001 4/15/03 4/10/03
4:11 AM6:21 AM0.79 4/10/030.79
6:26 AM 100 0.08 Engine
0.00 162 Engine
Delays derate 30 16437.0 Yes
16332.8 F No
HT001 4/16/03 12:51 PM HT001
4/16/03 4/14/03
12:56 PM 10:54 PM0.08 4/14/03 0.00
11:01 PM 162 0.12 Delays 162
Delays 16467.2
16436.4 S No
HT001 4/15/03 4:48 AM HT001 4/15/03 4/10/03
4:57 AM6:26 AM0.16 4/10/030.00
6:42 AM 162 0.27 Delays 128
0.27 WaitingStation
16332.8 F No
HT001 4/16/03 12:56 PM HT001
4/16/034/14/03
1:25 PM11:01 PM0.48 4/15/030.482:22 AM 100 3.34 Engine 100
3.34 Low engine oil level
Engine 16467.2
Low Yes
engine power F No Yes
16436.4 S No
HT001 4/15/03 4:57 AM HT001 4/15/03 4/14/03
5:57 AM3:28 PM0.99 4/14/030.993:39 PM 100 0.19 Air Intake & Exhaust 162
0.00 System Air cleaner plugged
Delays 16437.6
Waiting Yes
for Mechanic F No
16434.8 S No
HT001 4/17/03 2:13 AM HT001
4/17/03 4/15/03
2:22 AM2:55 AM0.14 4/15/030.00 3:23 AM 162 0.48 Delays 162
Delays 16479.7
Waiting for Mechanic S No
16437.0 F No
HT001 4/15/03 7:35 AM HT001 4/15/03 4/14/03
8:05 AM3:39 PM0.51 4/14/030.519:21 PM 120 5.69 Tires
5.69& Rims 100 Tire Check - Pos. #3Engine oil leaks
Engine 16439.1
/ Low Yes F
boost pressure No Yes
16434.8 S No
HT001 4/17/03 2:22 AM HT001
4/17/03 4/15/03
9:29 AM3:23 AM7.12 4/15/037.12 4:11 AM 100 0.79 Engine 100
0.79 Engine derate 31
Engine 16479.7derate
Engine Yes30 S No Yes
16437.0 F No
HT001 4/16/03 12:51 PM HT001 4/16/03 4/14/03
12:56 PM 10:54 PM0.08 4/14/03 0.00
11:01 PM 162 0.12 Delays 162
Delays 16467.2
16436.4 S No
HT001 4/17/03 9:43 AM HT001
4/17/03 4/15/03
9:58 AM4:48 AM0.25 4/15/030.00 4:57 AM 162 0.16 Delays 162
Delays 16479.9
16437.6 F No
HT001 4/16/03 12:56 PM HT001 4/16/034/14/03
1:25 PM11:01 PM0.48 4/15/030.48
2:22 AM 100 3.34 Engine 100
3.34 Low engine oil level
Engine Low16467.2 Yes
engine power F No Yes
16436.4 S No
HT001 4/17/03 9:58 AM HT0014/17/034/15/03
1:09 PM4:57 AM3.19 4/15/033.19 5:57 AM 100 0.99 Engine 100 Air Intake & Exhaust
0.99 Engine derate
System31 Air16479.9 Yes
cleaner plugged S No Yes
16437.6 F No
HT001 4/17/03 2:13 AM HT001 4/17/03 4/15/03
2:22 AM2:55 AM0.14 4/15/030.00
3:23 AM 162 0.48 Delays 162
Delays 16479.7
16437.0 F No
HT001 4/17/03 2:22 AM HT001 4/17/03 4/15/03
9:29 AM3:23 AM7.12 4/15/037.12
4:11 AM 100 0.79 Engine 100
0.79 Engine derate 31
Engine 16479.7derate
Engine Yes30 S No Yes
16437.0 F No
HT001 4/17/03 9:43 AM HT001 4/17/03 4/15/03
9:58 AM4:48 AM0.25 4/15/030.00
4:57 AM 162 0.16 Delays 162
Delays 16479.9
16437.6 F No
HT001 4/17/03 9:58 AM HT001 4/17/034/15/03
1:09 PM4:57 AM3.19 4/15/033.19
5:57 AM 100 0.99 Engine 100 Air Intake & Exhaust
0.99 Engine derate
System31 Air16479.9 Yes
cleaner plugged S No Yes
16437.6 F No
HT001 4/15/03 7:35 AM 4/15/03 8:05 AM 0.51 0.51 120 Tires & Rims Tire Check - Pos . #3 16439.1 Yes F No
60
Using Data to Drive Decisions
Questions? /
Comments?
Key Points / “Take-Aways”
• Use Data to develop Information for use as “Management Tools”,
• Apply meaningful Equipment Management metrics to quantify

performance,
• Analyze / Interpret Information to define critical issues,
• Understand the “big picture” & what is driving the end results …
“Drill Down” into issues by fleet / individual machine /
systems,
• Build action-oriented plans to address the key issues.
62
Using Data to Drive Decisions
END

Maintenance Performance Metrics: Using Data to Drive Decisions

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Maintenance Performance Metrics: Using Data to Drive Decisions

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Maintenance Performance Metrics

… Using Data to Drive Decisions

Reports serve three primary purposes:

 to provide basic performance information to top management,

 to identify problems or needed action, and

 to set priorities for the problem management (continuous

• To assess, quantify and document “as is” performance

• To highlight shortcomings and opportunities for improvement

• To establish priorities in the deployment of resources.

Cost / Hour Cost / Ton Tons / Hour

Rebuild Costs Component Lives Production Availability

What would you like to know?

Total Calendar Hours – mechanical Downtime Hours

Total Calendar Hours – MARC Downtime Hours

Scheduled Hours – mechanical Downtime Hours

Scheduled Hours – MARC Downtime Hours

What is the problem here?

What is the problem here?

Availability is driven by …..

 Defines the frequency of machine downtime events;

 Defines the average duration of machine downtime

Total Downtime Hours

Operating Hrs / Shutdowns

Availability Index (%) = (MTBS / (MTBS + MTTR))*100

 Defines a “normalized” availability KPI by ignoring the effects

Availability Index is the Availability

Machine Life Cycle

Downtime Reasons Detection Routines

• Frequency to be • Starting point of a

Ability to build a MTBS, MTTR & Availability Ability to maintain the

Maintenance Management Process

Preventive Maintenance Condition Monitoring Repair Management Component Management

Planning & Scheduling

Backlog Management Parts Management Training / HR

Machine Life Cycle

The Relationship: 1 / MTBS = 1 / MTBF + 1 / MTBnF

Equip. Start Repair Complete Repair Stop Labor Shop /

Scope & Goals of Project

 Overall fleet performance is substandard …

 MTTR is within acceptable limits (5.08 hours),

 MTBS is too low (20.70 hours).

 Overall fleet performance is substandard …

 MTBS is too low (20.70 hours).

 MTTR is within acceptable limits (5.08 hours).

 MTBS is cause of low availability.

Scheduled Downtime Hours

Scheduled Downtime Hours

 Low MTBS is result of unscheduled downtime.

 Evaluate / analyze individual machine performance.

 Evaluate / analyze fleet performance on a

 Take steps to increase % Scheduled Downtime.

 Truck No. HT002 is performing well below the

 Availability Index = 56.16%.

 MTBS is too low (7.40 hours).

 54 shutdowns in one month (30 days).

 Use Pareto analysis (significant few / trivial many)

 Apply same approach to another machine.

Develop an Action Plan

= 6.32% (impact of engines on fleet availability)

= Availability actual – Availability reference

Opportunity to Improve = 6.32% – 1.61% = 4.71%

• Time invested in PM is low (70% of reference).