Measuring Performance & Finding the “Best” Strategy

Maintenance Benchmarking
Measuring Performance Requires Targets
• Metrics
• Benchmarks
• Key Performance Indicators (KPI)
Metrics
“What can not be measured…
…Can not be improved”

Mechanical Availability
 Operated Hours
Mechanical Availability = X 100
(Op. Hours + Downtime)
If Mechanical Availability Is Important to You
• You need a strategy focused on the efficiency of
high frequency activities.
– Shift change
– Fueling & oil level checks
– Daily inspections
– Field repairs
– Lube service
– PM repairs (repair backlog)
If Mechanical Availability Is Important to You
• You need a strategy focused on metrics related to
mechanical availability.
– Mean Time Between Stoppages – MTBS
– Mean Time To Repair - MTTR
For High Frequency Activities You Need a
“Pit Crew” Mentality
Downtime-efficient Activity
1. Shift Change
2. Fuel & Oil Levels
3. Daily Inspections
4. Field Repairs
5. Lube Service
6. PM Repair Backlog
Downtime-efficient Activity
1. Shift Change • Hot seat changes
• People movers
• Carefully planned pre-
shift tasks
– Cleaning
– Inspection
– Oil top-off
Downtime-efficient Activity
1. Shift Change • Quick Disconnects
2. Fuel & Oil Levels • Fast Fill Equipment
• Steps & Ladders
• Lights
• Printed Documents
Downtime-efficient Activity
1. Shift Change • Well-planned Checklist
2. Fuel & Oil Levels • Training
3. Daily Inspections • Minimize Writing
– Check boxes
– Diagrams to mark
• Ladder
• Lights
Downtime-efficient Activity
1. Shift Change • Well-equipped Service
2. Fuel & Oil Levels Trucks
– Supplies
3. Daily Inspections
– Parts
4. Field Repairs
– Tools
– Literature
• A Good Record Keeping
System
Downtime-efficient Activity
1. Shift Change • Efficient Washing
2. Fuel & Oil Levels • Quick Disconnects
3. Daily Inspections – Fill & evacuation
4. Field Repairs • Kits - In the Bay
– Supplies
5. Lube Service
– Exchange items
• Breathers
• Strainers
• Magnetic plugs
Shop Area and Wash Bay
Exchange Kits Available for
Every Type of Machine.
• Increased efficiency and quality of work.
• Improved supervision.
Downtime-efficient Activity
1. Shift Change • Working From a Known
2. Fuel & Oil Levels Backlog (front log) List
3. Daily Inspections • Complete Work Order
– Downtime estimated
4. Field Repairs
– Repair time estimated
5. Lube Service
– Prepared instructions
6. PM Repair Backlog • Parts Already In the Bay

Planned Repairs
Repair Backlog Management
There is a big difference between…
Planning to do repairs
And
…Doing planned repairs

Your organization and your suppliers need

to understand the difference!
Repair Backlog Management
There is a big difference between…
Planning to do repairs
And
…Doing planned repairs

The difference is measured in machine

downtime!
Planned Repairs
• Ed’s simple test for finding out if repairs are true
planned repairs.

The parts arrive at the shop (or bay)

before the machine does.
If Mechanical Availability Is Important to You
• You need a strategy focused on the efficiency of
high frequency activities.
– Shift change
– Fueling & oil level checks
– Daily inspections
– Field repairs
– Lube service
– PM repairs (repair backlog)
If Mechanical Availability Is Important to You
• You need a strategy focused on metrics related to
mechanical availability.
– Mean Time Between Stoppages–MTBS
– Mean Time To Repair–MTTR
 Operated Hours
Mechanical Availability = X 100
(Op. Hours + Downtime)

MTBS
Mechanical Availability = X 100
(MTBS + MTTR)
Effect of MTTR on Availability (For MTBS=40)
100
90
80
70
60
50
40
30
20
2 4 6 8 10 12
MTTR (Hours)
Effect of MTBS on Availability (For MTTR=4)
100
90
80
70
60
50
40
30
20
5 30 55 80 105 130 155
MTBS (Hours)
Effect of MTBS on Availability (For MTTR=10)
100
90
80
70
60
50
40
30
20
5 30 55 80 105 130 155
MTBS (Hours)
T811 Monthly Maintenance Metrics
Mechanical Availability
The little things are bigger than you think!

1. Make sure high frequency activities are as

efficient as possible.
2. Track and analyze stoppages of any duration
(MTBS).
Metrics
“What can not be measured…
…Can not be improved”

Mechanical Availability
Metrics
“What can not be measured…
…Can not be improved”

Cost
If Mechanical Availability Is Important to You
• You need a strategy focused on the efficiency of
high frequency activities.
– Shift change
– Fueling & oil level checks
– Daily inspections
– Field repairs
– Lube service
– PM repairs (repair backlog)
If Mechanical Availability Is Important to You
• You need a strategy focused on metrics related to
mechanical availability.
– Mean Time Between Stoppages–MTBS
– Mean Time To Repair – MTTR
If Cost Is Important to You
• You need a strategy focused on optimizing major
component life.
– Lubricant quality
– Lube service accuracy
– Condition monitoring
– Operator technique
If Cost Is Important to You
• You need to monitor changes in application or
load factor.
– Fuel burn rates
– Payload management
– Underfoot condition management