To define the relevant maintenance and cost of KPIs for your equipment like APC Easy UPS SRV price in Pakistan. With the aim of increasing the productivity and profitability of your production assets?
The trend is towards TPM, total productive maintenance, an evolution of maintenance methods aimed at improving the performance of machines through a proactive approach. In fact, we are talking increasingly about preventive maintenance, which has a positive impact on the activity of your company, either in your expenses or in your income.
Of course, ” better safe than sorry “, but for this you must know how to detect the warning signs.
Main Benefits of Using Indicators
The main benefits of using indicators for your area is that you can identify poor performance points through quantitative data, they help you make decisions and better manage the maintenance process.
How can I generate a KPI?
Keep in mind that a KPI must have the following characteristics:
- Must be strategic
- Must have a goal
- Must be measurable
- Must be relevant
- It should help decision making
The monitoring of this data generates improvements that have important benefits such as:
- Cost reduction.
- Prevention of faults and breakdowns.
- Reduced downtime.
- Performance improvement.
- Impact on confidence in the maintenance area.
- Continuous improvement.
Whatever your maintenance plans, it is important to monitor the right maintenance indicators to adjust your strategy as needed. In this sense: Is there any maintenance KPI that should monitor more than another? How to choose the appropriate indicators and how to control them?
What is a maintenance KPI?
A maintenance indicator is essential for any company equipped with equipment whose proper functioning affects its activity and results (particularly in the industrial sector).
Maintenance management has many challenges:
- The preservation of production,
- Team profitability,
- Cost reduction (maintenance, replacement),
- Customer satisfaction,
the improvement of working conditions and, therefore, productivity!
The selection and application of maintenance indicators respond to the specific objectives of the company. These must consciously collect, by means of sensors or human intervention, and analyzed to transform them plan into actions to, according to the needs of each company (total increase in production, quality, welfare, and safety of its employees, etc.).
Maintenance KPIs can divide into two large families:
Key Performance Indicators, including:
- The availability of equipment,
- The reliability,
- Performance,
- The effectiveness,
- Mean time to failure
- The efficiency of the maintenance department, etc.
Performance indicators, especially in relation to compliance with the maintenance budget and stock management.
There are also those who consider that maintenance indicators can divide into 3 categories:
1. Running costs:
- Workforce,
- The consumption of resources (consumables, energy, etc.),
- The capitalization of assets (tools, machines, rentals), etc.
2. Maintenance expenses:
the type of maintenance (systematic preventive maintenance, conditional preventive maintenance, predictive preventive maintenance, immediate corrective maintenance, deferred corrective maintenance, etc.),
the consumption of spare parts,
subcontracting costs.
- Results of maintenance operations:
Corresponding to the performance indicators seen above (availability, reliability of equipment).
What are the maintenance of KPIs?
1. Calculation of reliability with the MTBF
The MTBF is one of the indicators that allows us to understand the reliability of a piece of equipment, along with the failure rate, or breakdown rate.
The MTBF is the average of the time of good operation between two failures (or Main Time Between Failure) and we calculate it, as follows:
Total operating time in each period/number of faults or breakdowns
MTBF calculation example, if the reference time is 160 hours, and if the accumulated time of the 5 breakdowns recorded in this period is 10 hours:
(160 h – 10 h)/5 = 30 hours
The failure rate is 5 failures/160 hours of operation = 0.03 failures per hour (3%).
Other reliability indicators can control:
MTTF (mean equipment operating time before first failure),
MUT (Mean Uptime After Repair).
MTBF-reliability-indicator
MDT Mean Down Time
2. Performance calculation with OEE
The Global Efficiency of Productive Equipment, or in English Overall Equipment Effectiveness, is the relationship between the real production and the maximum production.
We obtain this information and thanks to this calculation:
Availability rate = gross operating time / theoretical operating time
Rate of return = net operating time / gross operating time
Quality rate = uptime (optimal production) / net operating time
OEE calculation example:
- If the theoretical time = 10 h, the gross time = 8 h, the net time = 7 h, the useful time = 5 h 30
- Availability rate = 8/10 = 0.8 (80%)
- Rate of return = 7/8 = 0.875 (87.5%)
- Quality rate = 5.5/7 = 0.785 (78.5%)
Possible efficiency losses may be due to:
- The calendar (holidays, absences, etc.),
- Market fluctuations (falling orders),
- Shortage of stocks,
- Planned maintenance,
- Routine stops (cleaning, etc.),
- The breakdowns.
3. Calculation of the repair rate with the MTTR
The MTTR is the mean of the mean time to repair (Main Time to Repair) and calculated it as follows:
Total maintenance time/number of repairs
This rate not only gives a measure of the effectiveness of the interventions, but also an idea of the maintenance capacity of a team, which depends on criteria such as:
- The technical documentation,
- The ease of access,
- Ease of use, ergonomics,
- The security,
- The manufacturer’s criteria (design, after-sales service, availability of a component or service and cost of spare parts),
- The types of maintenance applied (monitoring of equipment or repair only in case of breakdown, rate of preventive and corrective maintenance).
4. Calculation of equipment availability
Availability depends on:
- Reliability (MTBF),
- Maintainability (MTTR),
- Maintenance Logistics (organization, maintenance and repair procedures, human resources, inventory management of components and spare parts, etc.).
This is how we calculated the total availability rate during a period T:
Usage and standby time/ (Use and standby time + maintenance time)
availability-indicators
5. The importance of the PMP indicator
The Planned Maintenance Percentage, or Planned Maintenance Percentage, indicates the degree of efficiency and success in the management of a company. There are two calculations:
Percentage of scheduled or preventive maintenance: it must be as close as possible to 100%, and calculated it as follows:
Sum of hours dedicated to preventive maintenance/total number of maintenance hours
Corrective maintenance index, whose calculation is:
Sum of hours dedicated to corrective maintenance/total number of maintenance hours.
6. Another 20 Examples of Maintenance KPI’s
- Indicator of maintenance expenses in relation to the replacement value of the equipment:
The Maintenance cost/value of maintaining the equipment
- Indicator of maintenance costs relative to the added value produced:
Also, Maintenance cost/added value produced
- Indicator of the relationship between the added value produced and the value to maintain the equipment:
The Maintenance cost/turnover related to production
- Indicator of the evolution of short-term maintenance costs:
And, Maintenance cost/production quantity
- Indicator of the evolution of the economic efficiency of maintenance:
Also, (Maintenance costs + downtime costs)/turnover related to production
- Indicator of the evolution of the technical efficiency of equipment maintenance:
Failure cost/ (maintenance cost + failure cost)
- Indicator of the evolution of production costs per unit produced:
- Proportion of preventive maintenance costs over total maintenance costs:
The Cost of preventive maintenance/maintenance costs (preventive + corrective)
- Indicator for the decision to substitute teams:
Cost of revisions, modernization, renovations/maintenance costs
- Current expense indicator (helps to decide between repairing or in-depth review):
Also, Cost of parts used/ (intervention staff costs + parts consumed)
- Stock Turnover Rate:
Value of holding stock/value of held assets
- Asset utilization rate:
Effective operating time/effective time available
- Operational availability of equipment:
Actual running time/total time
- Penalty for unavailability suffered by the user due to maintenance:
The Maintenance downtime/time required
- Downtime due to equipment maintenance:
Also, Maintenance downtime/total downtime
- Overall maintenance efficiency indicator:
Maintenance downtime/operating time or production quantity
- Importance of corrective maintenance in maintenance interventions:
Corrective maintenance time/maintenance time
- Time necessary to carry out corrective maintenance operations (administrative, logistical, preparation and technical time):
Corrective maintenance overtime/corrective maintenance time
- Proportion of interventions planned in all interventions carried out in the teams:
Expected working time/maintenance time
- Management of maintenance personnel and their training:
Training time or costs of maintenance staff/actual maintenance service
or maintenance training time or cost/company training time or cost
Several Maintenance Indicators
Although there are several maintenance indicators based on technical standards or the content provided by book authors, it is important to focus on the company’s objectives and the maintenance policy established that internally, so that the KPIs allow us to improve. management of the area and that this positively affects the results of the company.