OPEN WITH: I’m not here to tell you what Reliability Programs you should be following. I leave that to someone more qualified. What I AM here to tell you is HOW you can use your CMMS/EAM application (Maximo for this workshop) to measure your programs effectiveness once they are initiated within your strategic maintenance & reliability plan.Data Opens the Door to Success:You can use data to show the cost impact of utilities, equipment, and systems interruptions on business operations. If the roof is leaking in the hospital's operating room, the facility could experience serious contamination and lost revenue. Likewise, an upgrade could be hard to pass up on a new HVAC system if it will pay for itself in energy savings within a year and provide increased employee productivity from better air quality.
Rules of Thumb for Maintenance and Reliability Engineers – book by Ricky Smith and R. Keith MobleySMRP Publication – Maintenance & Reliability Body of Knowledge“PM Compliance is used to measure how much PM work was completed as scheduled. In this case it is a lagging indicator or result of how much PM work is completed when viewed in the context of work execution. When viewed as an indicator of equipment reliability, PM compliance is a leading indicator of the reliability process.”
If you are not capturing the data you want to measure, you can’t measure it!Lots of KPI Best Practices resources out there. Here is one about what NOT to do: OPEN The Seven Deadly Sins… Ricky Smith
Ask people for Examples of other types of KPI’s or Job Roles
Log into Maximo after this slide
Use KPI Manager application to build or edit KPI Query Expressions and to set KPI target, caution and alert.DEMO: Show example of “Average Emergency Completion Time” vs. “Average Emergency Response Time”. TRENDLINESShow how to display the KPI Graph and KPI List portlets on the Start Center. Use the Inventory Start Center.
Example of a canned BIRT report for Overall Equipment Efficiency dataDEMO: Drill down through this report.
Director, Business Development Solutions
Projetech, Inc. www.Projetech.com
Maximo Project Manager and Trainer for Projetech for
• Maximo Certified Deployment Professional
• Hobbies & Interests include: technology, data
analytics, fitness, social media
Support Reliability Strategies
with Key Performance Indicators
Using IBM Maximo®
Director Business Development Solutions,
• Reliability programs should support strategic
• Relevant Key Performance Indicators
– Measure program effectiveness
– Provide believable data
• KPI management and other Reporting options
• Must Meet Organizational Objectives
– Able to meet changing requirements for capacity, quality,
reliability, and cost.
– Most importantly, activities must always focus on ROI.
• Data Opens the Door to Success
– Using hard facts, you can link the physical facility to the core
business goals of your organization.
– Typical links include the ability to help organizations meet new
and evolving safety, environmental, health, and regulatory
• What's Your Top Priority?
– Focus on the "vital few" vs. the "trivial many.“
– Instead of doing routine maintenance on every single system in
the building, prioritize your maintenance activities.
– Data helps you decide what to perform and when to do it.
• Performance Indicator (PI’s)
– Any indicator measuring the performance of a
business process, work team, individual, piece of
equipment or plan in terms of its ability to meet its
desired levels of performance. 1
• Key Performance Indicators (KPI’s)
– Real-Time Measure
– Measures the overall performance of a particular
strategy or improvement initiative
• Use them to monitor effectiveness of reliability
1 The Maintenance Scorecard: Creating Strategic Advantage
• Lagging indicators (KRI) use historic data to build a
performance trend line. The trend shows progress and
can be projected forward to forecast likely progress.
• Leading indicators (KPI) use historic data to monitor
whether or not activities are producing good results.
• Use a mix of lagging indicators and leading indicators
to provide a clear understanding of what is happening
to the risk and performance of your operational assets
through maintenance efforts
What are You Measuring?
• Maintenance performance indicators reflect
achievement and progress in meeting an agreed
• Measure whether maintenance work successfully
removes risk of failure from your plant and equipment.
• Define Useful and Relevant KPI’s & PI’s 1
– Identify causes of equipment failures
– Effectiveness of PM / Predictive Maintenance (PdM)
– Measure effectiveness and efficiency of the Maintenance
– Measure the reliability improvement and operating risk
reduction results of the maintenance effort
Maintenance Effectiveness KPI’s
Mean time between failure
Mean time between repair
Overall Equipment Effectiveness
Time to complete EM work
Maintenance Efficiency and other
% Corrective maintenance
Inventory stock outs (Service
Safety, i.e., Lost time
• The information you need to manage your
reliability programs should be right at your
• If done correctly, your CMMS/EAM applications
will be able to provide you with the information
you need to analyze the success of your reliability
• It is important to know where data sources
reside, whether in Maximo or 3rd Party systems.
• Integrate when it makes sense.
Bad Data = Bad KPI
• Meaningful KPI’s need relevant, timely, accurate
and consistent data.
• Whenever possible, eliminate human error factor.
• Leverage automated data collection sources such
as PLCs, Building Automation Systems, and
• Collect data “at the source” via handheld or
• Use barcodes wherever it makes sense.
KPI’s by Job Function
Maintenance Supervisor KPI Examples
Maintenance cost per unit produced
MTBFF (Mean Time Between Functional Failure)
Maintenance labor cost (measured against target)
Maintenance material cost (measured against target)
Maintenance contractor cost (measured against target)
Overtime - %
Absenteeism - %
# of discipline violations
# of safety incidents
# of days without loss time accidents
# of environmental incidents
Maximo KPI Features
• Can be created from KPI Manager or 1-Click from an
end user application, such as Work Orders
• Can be graphical or list format
• Viewable on User’s Start Center (dashboard)
• Can link/drill down to other supporting KPI’s
• Shows trend lines
Other Reporting Options
• A good CMMS/EAM application will provide:
– Open source data access by third party
– Integrated and robust reporting applications
– User-friendly “ad-hoc” reporting tools for simple
– Ability to export data set results
• Open Source Platform report applications
• Support robust reporting requirements
(complex formulas/crosstabs, etc.)
– Optional integration with Crystal XI
Canned Maximo OEE %Report
OEE% by Site Report (available from Assets application)
Export Data Utilities
• On screen query results
• Canned and ad-hoc reports
• Reliability programs should support strategic
• KPI and other metrics should provide relevant,
accurate and timely information to support
reliability program success.
• Many KPI best practices resources available.
• Prioritize metrics.
• Maximo provides many reporting options to
support Key Performance Indicator reporting.
• The Maximo Manager’s guide to Business Performance
– Richard Taggs, Philip Sage, Monica Osana, Dante Tepora, John Mark de Asis, TEAM
• The Seven Deadly Sins in Measuring Asset Reliability
– Ricky Smith, CMRP
• The Maintenance Scorecard: Creating Strategic Advantage
– Darryl Mather
• KPI Dashboards (White Paper)
– Mileo Group www.mileogroup.com
• Projetech YouTube channel
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