CMRP

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1.1 Ratio of Replacement Asset Value (RAV) to Craft-Wage Head Count
Definition
The metric is Replacement Asset Value (RAV) of the assets being maintained at the
plant divided by the craft-wage employee headcount. The result is expressed as a ratio
in dollars per craft-wage employee.
Objetives
This metric allows for comparisons of the ratio of craft-wage personnel on a site with
other sites, as well as the benchmarking of data. The RAV is used in the numerator to
normalize the measurement given that different plants vary in size and replacement
value. The metric can be used to determine the standing of a plant relative to best in
class plants which have high asset utilization and equipment reliability, and generally
have lower maintenance craft-wage cost.
Formula
Ratio of Replacement Asset Value ($) to Craft-Wage Head Count =
RAV ($) ÷ Craft-Wage Headcount ( # of people )
Best practices
G. BEST IN CLASS TARGET VALUE
$8,000,000 to $9,000,000 per Craft Worker
Example
RAV ($)=624,500,000
Craft-Wage Headcount= 150
624,500,000/150 =4,160,000
Harminitation
This metric has not been harmonized with European standard EN 15341:
Maintenance Indicators
Time of meassurement
Yearly
1.3 Maintenance Unit Cost
Definition
The metric is the measure of the total maintenance cost required for an asset or facility
to generate a unit of production.
Objetives
To quantify the total maintenance cost to produce a standard unit of production over a
specified time period (e.g. monthly, quarterly, annually, etc.). This metric provides a
period over period trend of maintenance cost per unit produced. This measure can be
applied to a specific asset, a group of assets within a facility, across an entire facility or
across multiple facilities.
Formula
Maintenance Unit Cost = Total Maintenance Cost ÷ Standard Units Produced
Example
The total maintenance cost for the year was $2,585,000.
The total output from the manufacturing site in that same year was 12,227,500 kg.
Maintenance Unit Cost = $2,585,000 ÷ 12,227,500 kg
Maintenance Unit Cost = $0.21 per kg
Best practices
Non defined
Harminitation
This metric and its supporting definitions are similar to the indicator E3 in standard EN 15341
Time of meassurement
Anually

1.4 Stocked Maintenance, Repair, and Operating (MRO) Inventory Value as a Percent of Replacement Value
Definition
The metric is the value of maintenance, repair and operating materials (MRO) and
spare parts stocked on site to support maintenance, divided by the Replacement Asset
Value (RAV) of the assets being maintained at the plant, expressed as a percentage.
Objetives
This metric enables comparisons of the value of stocked maintenance inventory on site
with other plants of varying size and value, as well as to benchmarks. The RAV is used
in the denominator to normalize the measurement given that different plants vary in
size and value.
Formula
Stocked MRO Inventory Value per RAV (%) =[Stocked MRO Value ($) × 100] ÷ Replacement Asset Value ($)
Monetary Cost of Individual Storeroom Item =Quantity on Hand × Individual Item Cost
Example
If Stocked MRO Inventory Value is $3,000,000, and the Replacement Asset Value
(RAV) is $100,000,000,
Stocked MRO Inventory Value per RAV (%) =($3,000,000 × 100) ÷ $100,000,000= 3%
Best practices
Generally less than 1.5%; top quartile range is 0.3% to 1.5%, varying by industry
Harminitation
E7 in standard EN15341.
Time of meassurement
Anually or/and quarterly
1.5 Total Maintenance Cost as a Percent of Replacement Asset Value
Definition
The metric is the amount of money spent annually maintaining assets, divided by the
Replacement Asset Value (RAV) of the assets being maintained, expressed as a
percentage.
Objetives
This metric allows comparisons of the expenditures for maintenance with other plants
of varying size and value, as well as to benchmarks. The RAV is used in the
denominator to normalize the measurement given that plants vary in size and value.
Formula
Total Maintenance Cost per RAV (%) = [Total Maintenance Cost ($) × 100] ÷ Replacement Asset Value ($)
Example
If Total Maintenance Cost is $3,000,000 annually
Replacement Asset Value for the assets is $100,000,000
($3,000,000 × 100) ÷ $100,000,000
Total Maintenance Cost As a Percent of RAV = 3%
Best practices
Generally less than 3%; top quartile range is 0.7% to 3.6%, varying by industry
Harminitation
This metric and its supporting definitions are similar to EN 15341 Indicator E3.
Time of meassurement
Anually
2.1.1 Overall Equipment Effectiveness (OEE)
Definition
The metric is a measure of equipment or asset performance based on actual
availability, performance efficiency, and quality of product or output when the asset is
scheduled to operate. Overall equipment effectiveness (OEE) is typically expressed as
a percentage.
Objetives
This metric identifies and categorizes major losses or reasons for poor asset
performance. It provides the basis for setting improvement priorities and beginning root
cause analysis. OEE can also foster cooperation and collaboration between operations,
maintenance and equipment engineering to identify and reduce or eliminate the major
causes of poor performance. Maintenance alone cannot improve OEE.
Formula
Overall Equipment Effectiveness (%) =
Availability (%) × Performance Efficiency (%) × Quality Rate (%) Availability (%) =
[Uptime (hrs) × 100] ÷ [Total Available Time (hrs) – Idle Time (hrs)]
Uptime (hrs) = Total Available Time (hrs) – [Idle Time (hrs) + Total Downtime (hrs)]

Total Downtime (hrs) =

Scheduled Downtime (hrs) + Unscheduled Downtime (hrs)

Performance Efficiency (%) =

[Actual Production Rate (units per hour) ÷ Best Production Rate (units per hour)] × 100

Quality rate % =
[(Total Units Produced – Defective Units Produced) ÷ Total Units Produced] × 100
Best practices
85% to 100% batch type manufacturing
90% to 100% continuous discrete manufacturing
95% to 100% continuous process
Availability >90%
Quality >99%
Performance >95% equals a 85% to 100% OEE

Example
An example of the calculation of OEE percentage based on OEE data for one day (24
hours) for “Machine D” operation are shown in the table below.

Major Losses
Total Available Time
Idle Time

Scheduled Downtime
No production, breaks, shift change, etc.
Planned maintenance
Total Scheduled Downtime

Un-scheduled Downtime
Waiting for operator
Failure or breakdowns
Setups & changeover
Tooling or part Changes
Startup & adjustment
Total Un-Scheduled Downtime

Total Downtime
(scheduled + unscheduled)

Uptime

Availability
Performance efficiency losses
Minor stops
Reduced speed or cycle time

Performance efficiency

Quality & yield losses

Scrap product / output
Defects, rework
Yield / Transition
Input material flow
Rejected units produced
Good units produced

Quality rate
Overall equipment effectiveness %
Harminitation
Not harmonized

Time of meassurement
Real Time – Hourly or per operating shift
Daily – Summary report of OEE performance
Period Trending – Daily, weekly, monthly, quarterly and/or annual
comparisons
2.1.2 Total Effective Equipment Performance (TEEP)
Definition
This metric is a measure of equipment or asset performance based on actual utilization time,
availability, performance efficiency and quality of product or output over all the hours in the
period. TEEP is expressed as a percentage.
Objetives
The objective of this metric is to measure how well an organization extracts value from
its assets. It provides the basis for setting improvement priorities and root cause
analysis. Production losses are graphically depicted in Figure 1 based on the time
elements in Figure 2.
Formula
TEEP (%) =Utilization Time % × Availability % × Performance Efficiency % × Quality Rate %
Utilization Time % =[Total Available Time (hrs) – Idle Time (hrs)] ÷ Total Available Time (hrs)
Availability % = Uptime (hrs) ÷ [Total Available Time (hrs) – Idle Time (hrs)] × 100
Uptime (hrs) = Total Available Time – (Idle Time + Downtime)
Downtime (hrs) = Scheduled Downtime + Unscheduled Downtime
Performance Efficiency % = [Actual Production Rate (units per hour) ÷ Best Production Rate (units per hour)] × 100
Quality Rate % = [(Total Units Produced – Defective Units Produced) ÷ Total Units Produced] × 100
Time of meassurement
Time basis: Monthly, quarterly and/or annually.

Major Losses

Total Available Time

Idle Time

Utilization Time

Scheduled Downtime
Waiting for operator
Failure or breakdowns
Setups & changeover
Tooling or part Changes
Startup & adjustment
Total Un-Scheduled Downtime

Total Downtime (scheduled +unscheduled)

Uptime

Availability

Performance efficiency losses

Minor stops
Reduced speed or cycle time

Performance efficiency

Quality & yield losses

Scrap product / output
Defects, rework
Yield / Transition
Input material flow
Quality rate
Total Effective Equipment Performance %
Best practices
85% to 100% (Industry Specific)
Availability >90%
Quality >99%
Performance >95%
Utilization = 100%
2.2 Availability
Definition
Availability is the percentage of time that the asset is actually operating (uptime)
compared to when it is scheduled to operate. This is also called operational availability.
Objetives
Availability provides a measure of when the asset is either running or is capable of
running. It is a measure of an asset’s ability to be operated if required.
Formula
Availability % = {Uptime (hrs) ÷ [Total Available Time (hrs) – Idle Time (hrs)]} x 100
Uptime = Total Available Time – (Idle Time + Downtime)
Down Time = Scheduled Downtime + Unscheduled Downtime
Example

Total Available Time

Idle Time

Downtime Summary
A. Scheduled Downtime:
1. Preventive maintenance mean time
2. Scheduled shift breaks

Total Scheduled Downtime

B. Unscheduled Downtime:
1. Waiting for operator
2. Failures or breakdowns
3. Setups and changeovers
4. Tooling or parts changes
5. Start-ups and adjustments
Total Unscheduled Downtime

C. Uptime:

H. Availability:(% of time an asset is operating.This is the metric referenced in OEE)

Pag 74
 Data
24 (hrs)
8 (hrs)

0
0.66 (hrs)
1.00 (hrs)
 1.66 (hrs)

0
0.46 (hrs)
0.33 (hrs)
0.56 (hrs)
0.23 (hrs)
0.50 (hrs)
2.08 (hrs)

3.74 (hrs)

12.26 (hrs)

76.63%
(Count)
10 events
100 vs. 167 units

59.88%

(Count)
2
1
5
0
8
92

92.00%
42.21%
 Data

24 (hrs)
8 (hrs)

66.67%

0
0.46 (hrs)
0.33 (hrs)
0.56 (hrs)
0.23 (hrs)
0.50 (hrs)
2.08 (hrs)

3.74 (hrs)

12.26 (hrs)

76.63%

(Count)
10 events
100 vs. 167 units

59.88%

(Count)
2
1
5
0
92.00%
 28.14%

Data (Hours)
720
240

(Hours)

30
19.8

49.8

(Hours)
13.8
9.9
16.8
6.9
15
112.2

367.8

76.63%
Comments
24 hours in one day
Not required 8 hours per day

Meeting & shift change

Monthly PM
Mechanical drive coupling
2 size changes
Screw station bits
1st shift Monday

1.66 + 2.08 = 3.74 hours

Uptime = (24 - 8) - 3.74 = 12.26 hrs

Availability =12.26 ÷ (24 - 8) × 100 = 76.63%

Machine jams
Design rate: 12.5 units/hour
Performance efficiency =
(100 ÷ 167) x 100 = 59.88%

Waste, non-salvageable

Startup & adjustment related

Waiting for raw materials
2+1+5=8
100 – 8 = 92 good units
Quality Rate =
(92 ÷ 100 ) × 100 = 92.00%
76.63 x 59.88 x 92.00 = 42.21%
Comments and calculation

24 hours in one day

Not required 8 hours per day
Utilization Time =
(24 - 8) ÷ 24 × 100 = 66.67%

Mechanical drive coupling

2 size changes
Screw station bits
1st shift Monday

1.66 + 2.08 = 3.74 hours

Uptime = (24 - 8) - 3.74 = 12.26 hrs

Availability =[12.26 ÷ (24 - 8)] × 100 = 76.63%

Machine jams
Design rate: 12.5 units/hour
Performance Eff =
(100 ÷ 167) × 100 = 59.88%

Waste, non-salvageable

Startup & adjustment related

Waiting for raw materials
Quality Rate =(92 ÷ 100 ) × 100 = 92.00%
66.67 × 76.63 × 59.88 × 92.00 =28.14%

Comments
24 hours for 30 days
Power outage 20 hours + Lack of Feedstock 220 hours

30 event

Uptime = 720 – 240 – 49.8 – 112.2

Availability =367.8 ÷ (720 - 240) x 100 = 76.63%

RAV Replacement Asset Value = Estimated Replacement Value ERV
FTE full-time equivalents
MRO maintenance, repair and operating materials
TEEP Total Effective Equipment Performance
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