Maintenance metrics and Maintenance KPIs are critical to measure the performance of your processes and organization as a whole. You must set a quality benchmark to measure the current effectiveness of the processes and understand where you have to make improvements.
They are the 6 asset maintenance KPI metrics that you need to focus on.
- Preventive maintenance
- Planned and Unplanned Maintenance
- Root Cause
- Maintenance Backlog
Let’s learn these metrics in detail.
What Are Maintenance Metrics?
Maintenance metrics are key performance indicators (KPIs) used to track and measure the performance of maintenance processes. These metrics provide valuable insights into how well assets are being maintained, where resources are being allocated, and how effective maintenance strategies are at preventing equipment failures and downtime. There are 6 asset maintenance metrics that you need to focus on.
Mean Time to Repair (MTTR)
MTTR is the average time that is required to restore failed equipment to working order and return to production. When you have access to this metric, you will gain knowledge of how your organization must respond to planned repairs or unplanned equipment problems. You will also have evidence of how long the production was interrupted and what the average repair time of each component was. An EAM software can help you calculate this metric accurately.
Mean Time Between Failure (MTBF)
MTBF is the average time between equipment failures. Use CMMS software to measure this KPI for individual equipment. It is one of the most efficient ways of analyzing the reliability of an asset and predicting its future performance. It is an important metric when you are scheduling preventive maintenance to reduce downtime and ensure that you do not over-maintain your assets.
One of the most effective ways of reducing asset downtime and increasing its lifespan is by performing regular preventive maintenance on the equipment. This will reduce the likelihood of equipment failure. Asset management software helps in monitoring and tracking whether the scheduled work has been carried out or not and if it was done on time.
You must measure it so that you can assess the effectiveness of the preventive maintenance program effectively. Maintain a preventive maintenance strategy and stick to it because if you don’t, you can most likely expect failures and disruptions.
Planned Vs Unplanned Maintenance
This maintenance KPI will help you determine the maintenance maturity in your organization. If it lies north of 90%, it is considered excellent; over 70% is acceptable with room for improvement and anything less than that is considered problematic for the business. This maintenance metric stored in preventive maintenance software helps you evaluate the effectiveness of your preventative maintenance program and monitor improvements over time.
If there is an issue, you will put all your efforts into resolving it as quickly as possible. However, you shouldn’t forget about the issue once it is resolved. Try to get a deeper understanding as to why the problem occurred and what its root cause was. Digging deep will let you have a better understanding of recurring problems, which will help the maintenance team in the long run.
If the issue is caused repeatedly due to human error, it indicates that your staff requires more training and you must schedule some training sessions using maintenance management software. Overused assets, low-quality spares and technician skills can all hurt the maintenance department in the long run. You need to identify such issues and their root causes so that you can effectively put remedial actions in place.
It is a common problem that numerous organizations face. Employ asset planning software to track the maintenance logs regularly so that you can be aware if any backlog is being created or not. The longer you leave the backlogs, the more compliance issues or breakdown of assets will crop up. Encourage transparency as it will allow you to know what work orders are overdue and prioritize them accordingly.
Why Are Maintenance Metrics Important?
Maintenance metrics provide a range of benefits for organizations that rely on equipment and assets to achieve their goals. By tracking and measuring maintenance performance, organizations can:
- Identify areas for improvement: Maintenance KPI metrics provide valuable insights into how well maintenance processes are performing. By identifying areas for improvement, organizations can optimize their maintenance strategies and improve asset reliability.
- Reduce downtime: By tracking metrics such as MTTR and PMP, organizations can identify opportunities to reduce downtime and improve equipment availability.
- Increase efficiency: By measuring OEE, organizations can identify areas where equipment is not being utilized efficiently, and take steps to optimize utilization.
- Make informed decisions: By having access to data on maintenance performance, organizations can make informed decisions about resource allocation, equipment replacement, and maintenance strategy.
How to Implement Maintenance Metrics?
Implementing maintenance KPIs requires a structured approach. The following steps can help organizations implement maintenance metrics effectively:
- Define objectives: Identify the key objectives for implementing maintenance metrics. What do you hope to achieve by tracking performance?
- Select metrics: Select the metrics that are most relevant to your objectives. Consider which metrics will provide the most valuable insights into maintenance performance.
- Establish baselines: Establish baseline metrics to provide a starting point for tracking performance. This will allow you to measure progress over time.
- Collect data: Collect data on maintenance performance, using software systems or other tools to automate the process where possible.
- Analyze data: Analyze the data collected to identify trends, patterns, and areas for improvement.
- Take action: Use the insights gained from the data analysis to take action and optimize maintenance strategies.
- Review and refine: Continuously review and refine your maintenance metrics and maintenance strategies to ensure ongoing improvement.
Maintenance metrics are essential for effective maintenance management. By tracking performance indicators, organizations can gain valuable insights into maintenance performance, and areas for improvement, and make informed decisions about resource allocation and maintenance strategies. Implementing maintenance metrics requires a structured approach, but the benefits – including reduced downtime, increased
If you can’t measure these maintenance metrics, you won’t be able to improve them. It is possible to reduce cost, failure and downtime if you can correctly implement, measure and track these maintenance metrics. NEXGEN’s EAM can help contribute to effective business operations by managing and measuring these maintenance KPIs accurately. When you implement CMMS correctly, you are essentially setting your facility and organization up for long-term success.