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Qwikratio marshall

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  • 1. Qwik Ratio Exercise ©Marshall Institute, Inc 1800 Tillery Place, Suite i Raleigh, NC 27604 1-800-637-0120 1-919-834-3722 www.marshallinstitute.com
  • 2. QWIK RATIO EXERCISE Directions: Step 1. Gather the Data Complete the data table, Page 1 of the exercise. Note: If you don’t have the data, provide a “best estimate” number. Step 2. Calculate the Ratios Using the value in the data table (Page 1), calculate the indicated rations in each of the 10 boxes on Page 2. For example, to calculate the first ratio, Maintenance Cost, % ERV, do the arithmetic in the box: Line #6 / Line #8 Score your result on a scale of 1-10 based on the scale shown for each ratio. <2.5% 3.0% >3.5% Points 10 5 1 Note: If you don’t have the data, even an estimate of the data, and can’t do the calculation from the data, then at least estimate (or guess) the ratio and score it 1-10 on the scale. You now should have a 1-10 score in each of the 10 boxes. Step 3. Plot the Radar Chart (“spider diagram”) Using the radial scale of 1–10 on the radial graph (page 3), plot each of the 10 box scores on its corresponding radial line. Connect the points. Color the diagram. INTERPRETATION This chart has been designed to plot industrial averages at about 5 points, and “world class” or “best of class” numbers about 10 on the chart. That means that to the degree that you are “world class” you will have lots of area under the curve, most ratios close to 10 (say 7 or better). To the degree that you have “opportunity” for improvement, your values will be low, and not much area under the curve (say 0–3); there will be lots of “white” space on the outside of the curve. See the example plot on Page 4. ©Marshall Institute, Inc. r1 1-800-637-0120 Instructions
  • 3. QWIK RATIO CHART DATA ELEMENTS 1. How many total man-hours did your maintenance operation use (do not count contract services or capital projects)? This would be maintenance activities for effort-hours the year to include providing service for facilities, equipment, grounds, etc. 2. Of the hours listed above in #1, how many man-hours were dedicated to Preventive Maintenance activities? PM tasks are planned and scheduled activities conducted a certain frequencies designed to prolong equipment life and provide early warning of impending problems, such as cleaning, lubricating, effort-hours adjusting, inspecting, and minor repair/replacement. Does not include major repairs or “opportunity” repairs. 6. What were the total maintenance expenditures for your plant (less capital projects or other ‘non-maintenance’ related costs)? Include the total costs to maintain facilities and equipment (and grounds, if appropriate) to include labor, parts, materials, maintenance contractors, etc. Include all maintenance expenditures for all maintenance departments at your site. $ 8. At current prices, how much would it cost to replace you entire facility (Estimated Replacement Value)? This is the cost of replacing the facility and $ equipment at today’s prices (less real estate). 10. How many maintenance hourly craftspeople or non exempts, such as technicians, electricians, mechanics, pipefitters, and millwrights, did you have working full-time at you plant? 14. How many full-time maintenance planners did you have? Maintenance planners plan, prepare and sometimes schedule maintenance activities. Planning includes all activities necessary to ensure the proper parts, tools, and other supplies are allocated and sequenced for the craftsmen at the start of a job. 15. How many maintenance support personnel did you have working at your plant? Support personnel include planners, supervisors, maintenance engineers, maintenance clerical personnel, maintenance managers, maintenance inventory control personnel, etc. 17. What was your overall average maintenance overtime percentage? % 18. Of the total maintenance hours listed in questions #1, above, how many hours of work were formally planned and scheduled in advance of the job versus effort-hours emergency, crisis, or unscheduled work in general. 19. Of the total maintenance hours listed in question #1, above, how many hours were ‘captured’ (charged) on a work order. 23. What was your overall inventory turn rate:? (Overall turn rate is generally calculated as total dollars consumed divided by average dollar inventory value, or storeroom dollars issued over dollars storeroom value.) 24. What was your average service level? (Service level is generally defined as the percentage of time stocked parts are available when requested. Or, the number of issues satisfied divided by the number of issues requested.) % 27. How many total man-hours of formal training did maintenance craftspeople receive? (Do not include OJT or other informal forms of training.) effort-hours ©Marshall Institute, Inc ©Marshall Institute, Inc. r1 1-800-637-0120 1
  • 4. QWIK RATIOs 1. Maintenance Cost, % ERV Line #6 / Line #8 <2.5% 3.0% >3.5% Points 10 5 1 2. Planned Maintenance, % Line #18 / Line #1 >90% 90-75% 74-60% 59-40% <40% 0 Points 10 8 6 4 2 0 3. PM Effort Hours, % Line #2 / Line #1 >50% 34% 25% <10% Points 10 5 2 0 4. Effort Hours Charged to Work Orders, % Line #19 / Line #1 >90% 89-80% 79-70% 69% 0% Points 10 8 7 5 0 5. Inventory Turns Line #23 >2.0 1.0 <.5 Points 10 5 0 6. Service Level Line #24 >98% 95% 92% <92% Points 10 5 2 0 7. Maintenance Overtime, % Line #17 <5% 10% 15% >15% Points 10 5 2 0 8. MTCE Planners / MTCE Hourly Line #14 / Line #10 1/<25 1/30 1/>35 No Planners Points 10 5 2 0 9. MTCE Support / MTCE Hourly Line #15 / Line #10 1/<3.5 1/4 1/5 1/>10 Points 10 5 2 0 10. Training Hours / Craftsperson (per yr) Line #27 / Line #10 >100 50 0 Points 10 5 0 2 1-800-637-0120 www.marshallinstitute.com
  • 5. QWIK RATIO CHART 10 TRNG 9 ERV 8 7 6 SRATIO 5 PLAN 4 3 2 1 PRATIO PM OT WO SERV INV 1 ERV $, % ERV 2 PLAN % PLANNED MAINTENANCE 3 PM % PREVENTIVE MAINTENANCE 4 WO % HRS CHARGED TO WOs 5 INV INVENTORY TURNS 6 SERV INVENTORY SERVICE LEVEL, % 7 OT OVERTIME, % 8 PRATIO PLANNED/HOURLY RATIO 9 SRATIO SUPPORT/HOURLY RATIO 10 TRNG TRAINING HRS/CRAFTSPERSON ©Marshall Institute, Inc. r1 1-800-637-0120 3
  • 6. Example Qwik Ratio Plot  4 1-800-637-0120 www.marshallinstitute.com

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