Maintenance and Reliability Metrices

Sr
Pillar
1
2
3
4
Pillar
1
2
3
4
5
6
Pillar
1
2
3
4
5
6
7
8
9
Pillar
1
2
3
4
Pillar
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Metric
1 Business and Management
Ratio of RAV to Craft-Wage Head Count
Maintenance Unit Cost
MRO Inventory Value as a Percent of RAV
Total Maintenance Cost as a Percent of RAV
2 Manufacturing Process Reliability
Overall Equipment Effectiveness (OEE)
Total Effective Equipment Performance (TEEP)
Availability
Uptime
Idle Time
Utilization Time
3 Equipment Reliability
Systems Covered by Criticality Analysis
Total Downtime
Scheduled Downtime
Unscheduled Downtime
Mean Time Between Failures (MTBF)
Mean Time to Repair or Replace (MTTR)
Mean Time Between Maintenance (MTBM)
Mean Downtime (MDT)
Mean Time to Failure (MTTF)
4 Organization and Leadership
Rework
Maintenance Training Cost
Maintenance Training Hours
Maintenance Training Return on Investment (ROI)
5 Work Management
Corrective Maintenance Cost
Corrective Maintenance Hours
Preventive Maintenance Cost
Preventive Maintenance Hours
Condition Based Maintenance Cost
Condition Based Maintenance Hours
Maintenance Shutdown Costs
Planned Work
Unplanned Work
Actual Cost to Planning Estimate
Actual Hours to Planning Estimate
Planning Variance Index
Planner Productivity
Reactive Work
Proactive Work
Schedule Compliance Hours
Schedule Compliance Work Orders
Standing Work Orders
Work Order Aging
Work Order Cycle Time
Planned Backlog
Ready Backlog
PM & PdM Work Orders overdue
PM & PdM Yield
PM & PdM Compliance
Craft Worker to Supervisor Ratio
Craft Worker to Planner Ratio
Direct to Indirect Maintenance Personnel Ratio
Craft Workers on Shift Ratio
Overtime Maintenance Cost
Overtime Maintenance Hours
Stores Inventory Turns
Vendor Managed Inventory
Stock outs
Inactive Stock
Storeroom Transactions
Storeroom Records
Maintenance Material Cost
Wrench Time
Continuous Improvement Hours

Target Value

UOM

8-9

M USD

0.3 - 1.5
0.7 - 3.6

%
%

95 - 100
85 - 100

%
%

Availability x Performance x Quality

Utilization x OEE

>95 - 98

For batch / continuous process respectively

No demand / raw material / administrative idle time
Scheduled running time in a calander year

<0.5 - 2

Zero
4
80

%
%
Hrs / yr

20 - 25

45 - 50
>90
<10
15
10

<
>
>
>
<

10
80
90
90
10

%
%
%
%

%
%
%
%
%

4-6
2-4
<5

weeks
weeks
%

> 90
12:1
> 30:1
3-5
Zero
<5
5 - 10
>3

%
Ratio
Ratio
Ratio
target
%
%
Ratio

<2
<1
100 - 140
5000
50
50 - 55
> 5 - 15

%
%
trans.
SKUs
%
%
%

Explanation
Comparison of craft wage % from site to site
Per unit of output produced

%age of total available maintenance man hours

5age of total maintenance wages
Training hours per total no of employees

Fraction
Fraction
Fraction
Fraction
Fraction
Fraction
Fraction
Fraction
Fraction

of
of
of
of
of
of
of
of
of

total
total
total
total
total
total
total
total
total

maintenance
labor hours
maintenance
labor hours
maintenance
labor hours
maintenance
labor hours
labor hours

cost
cost
cost
cost

% WO closed with 20% cost variance

Planned labor hours or no of planned jobs per month
Ratio of work (hrs) that break into weekly schedule
Work planned a week before execution

Also called blanket Wos

Age of open WOs in days
Time from WO creation till it is closed in CMMS
Work that is planned but not scheduled
Fully planned work waiting assigned labor only
Measures if PMs are performed on time or late
Volume of CM identified through PM / PdM
Fraction of PM Wos completed within 10% variance

Ratio of labor to supervisors, engrs, clerks etc

Fraction of total maintenance labor cost
10% only if OT is for planned jobs otherwise 5%
Ratio of value of stock purchased to stock on hand
Ratio of vendor managed SKUs to total SKUs
Ratio of requests with stockouts to total requests
Stock not used in past 12 months
Total transactions per MWH clerks per day
Ratio of total no of SKUs to total storeroom clerks
Fraction of total maintenance cost