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