Presentation for the AFE Maintenance Council

1. Maintenance Council
Maintenance Metrics
An AFE Maintenance Council
Presentation
Presenter: Kate Kerrigan
AFE Presentation: Maintenance Metrics 1

2. Maintenance Council
Maintenance Metrics
• Purpose of Metrics
• Know your audience
• Metrics: How to drive to Success
• Presentation Techniques
AFE Presentation: Maintenance Metrics 2

3. Maintenance Council
Purpose of Metrics
AFE Presentation: Maintenance Metrics 3

4. Maintenance Council
Purpose of Metrics
• Drive Improvement
– Eliminate or minimize problems
– Save money
– Create capacity
• Set Priorities
– Establish goals and how they are measured
– Create common priority among diverse depts
– Set milestones and celebrate success
AFE Presentation: Maintenance Metrics 4

5. Maintenance Council
Purpose of Metrics
If you don’t know where you are going,
any road will take you there.
"Would you tell me, please, which
way I ought to go from here?"
"That depends a good deal on
where you want to get to," said the
Cat.
"I don't much care where--" said
Alice.
"Then it doesn't matter which way
you go," said the Cat.
AFE Presentation: Maintenance Metrics 5

6. Maintenance Council
Know Your Audience
AFE Presentation: Maintenance Metrics 6

7. Maintenance Council
Types of Audience
• Maintenance • Other Supervisors
• Managers • Production
• Supervisors • Warehouse
• Planners • Customers
• Crew
– Internal
• Managers • Operators
• Peers • Quality
• Bosses – External
• Functional • Service shops
• Indirect • Facility Users
AFE Presentation: Maintenance Metrics 7

8. Maintenance Council
Know your Audience
• Many metrics are appropriate for multiple
audiences
• Use no more than 3 metrics as a
communication tool to each audience
• Only communicate a metric that the
audience is directly effected by
• Maintenance managers and supervisors
need to know all metrics and when to
apply them
AFE Presentation: Maintenance Metrics 8

9. Maintenance Council
Metrics and Their Definitions
• Understand the formula used by each metric
– Only compare like to like
– Do not depend on your CMMS unless you
understand the formula used
• Do not let industrial maintenance be
confused with a service shop
• Mentoring others is a responsibility
• There is no silver bullet
AFE Presentation: Maintenance Metrics 9

10. Maintenance Council
Metrics for Managers
• Maintenance Cost / Unit
– Total $ spent in Maint / Units produced
– This is needed to help set budgets
– Trend
• Determine if maintenance is getting more efficient.
• Can be misleading if volumes swing dramatically.
– Different organizations put different costs in maintenance,
do not use this to compare outside your organization
• Customer Satisfaction
– Need vs Want
– Equipment as the Customer
AFE Presentation: Maintenance Metrics 10

11. Maintenance Council
Overall Equipment Effectiveness
(OEE)
• It provides an overall evaluation of how
capital assets are utilized
Good Units Produced
(Total units – Quality Defects)
Total Units asset is * 100 = OEE
capable of producing
Need to define – Availability & Expected Capability
AFE Presentation: Maintenance Metrics 11

12. Maintenance Council
Mean Time Between Failure-MTBF
• Mean of What
– Individual machine (Widget Maker #3, Turbine 2)
– Category of machines (Presses, Box Formers, …)
– Sub-systems (Pumps, Conveyors, …)
– Component (Bearings, Prox Switches, …)
• What is a Failure
– Each Work order (are PMs included?)
– Breakdowns only
– Work order over a Dollar or Time Threshold
AFE Presentation: Maintenance Metrics 12

13. Maintenance Council
Metrics For Maintenance
• PM or PdM on time completion Rate
– On-time should be within 10% of Frequency
• Monthly should be done within 3 days of due date
• Weekly on the due date
– Goal should be between 90-100% on time
– Correlate with Breakdowns
• If breakdowns are not decreasing, PM program not working
• Percent of total time spent by Work Order Type
– Need to account for 100% of maintenance time for this to
be useful
– Long term indicator of Reactive or Proactive Maintenance
AFE Presentation: Maintenance Metrics 13

14. Maintenance Council
Planning Metrics
• Mean time to repair (MTTR)
• Backlog – usually in hours
• Schedule Attainment
• Planning effectiveness
– Dollars
– Time
– Priority or RIME Ranking Index for Maintenance
Expenditures (RIME)
AFE Presentation: Maintenance Metrics 14

15. Maintenance Council
Facility Metrics
• Maintenance Dollars as a percent of
Replacement Asset Value
– Total Facility (Measure of Efficiency and Upkeep)
– To determine repair/rebuild/swap/replace
• Energy usage
– Water consumption
– Electricity consumption
– Steam or Compressed Air Cost
• Environmental
– Waste hauling fees or tons
AFE Presentation: Maintenance Metrics 15

16. Maintenance Council
Inventory Metrics
• Spare Parts
– Capital or Emergency Spares (e.g. a transformer)
• Unit cost
• Spare for how many users/entities
– Wear items
• Inventory Turns
• Total inventory value
• Stock Outs
• Life of critical components (Reliability)
– Free issue stock (often vendor managed)
• Total Value
AFE Presentation: Maintenance Metrics 16

17. Maintenance Council
How to Drive Success
AFE Presentation: Maintenance Metrics 17

18. Maintenance Council
Metrics: How to drive to Success
• Stay Focused
– Choose your driving metrics and stick with them
– Publish results timely (weekly, monthly, quarterly)
• Set a goal
– Involve others when setting goal
– Set stretch but realistic goals
– If measuring is new, set escalating goal to get quick
results
AFE Presentation: Maintenance Metrics 18

19. Maintenance Council
Driving Success
• Understand how metric is influenced
– Know the calculation formula
– Have complementary metrics to avoid “pencil
whipping” or sacrificing long term gains for
short term ones
• PM completion rate & Break Down Frequency
• % Work Proactive & Response to Call time
• Always know “why” when metric changes
dramatically (Down or Up)
AFE Presentation: Maintenance Metrics 19

20. Maintenance Council
Driving Success
• Comment on Results
– Celebrate Milestones
– Pep talk Failures to reach objectives
• Make metric meaningful to user
– Ex: 5 minutes of downtime = $1,000
• Delve into reliability
– Infant Mortality
– Chronic Failures (Bad Actors)
– Skills Reviews and Training
AFE Presentation: Maintenance Metrics 20

21. Maintenance Council
Plan time to Analyze
• Goal
• Gap to Goal
• How Maintenance Metrics Contribute to
overall success
• How do metrics fit into reliability strategy
AFE Presentation: Maintenance Metrics 21

22. Maintenance Council
Presentation
Techniques
AFE Presentation: Maintenance Metrics 22

23. Maintenance Council
Chart vs List
• Charts
– Show trends
– Very visual
– Good for Quick reference
– Limited Data Points
• Lists
– Can be sorted many ways
– Require good audience understanding of
values
– Good for detailed reviews
AFE Presentation: Maintenance Metrics 23

24. Maintenance Council
Comparative Information
• Goal Lines
– Set Target
– Show Gaps
• Previous Time Period (Year’s) Results
• Linear Trend Slope
– Climbing or Descending
– Sharp or Gradual
• Best in Class Results (Internal or External)
AFE Presentation: Maintenance Metrics 24

25. Maintenance Council
Keep it Simple Average
Maintenence Schedule Attainment By Crew
Busy 100%
90%
80%
70% A Crew
60% B Crew
50%
40% Day Crew
30%
20%
10%
0%
e
6
4
1
8
6
3
23
30
13
20
27
11
18
25
15
22
29
13
20
27
ag
4/
5/
6/
6/
7/
8/
3/
3/
4/
4/
4/
5/
5/
5/
6/
6/
6/
7/
7/
7/
er
Av
Crazy Maintenence Schedule Attainment By Crew A Crew
B Crew
100% Day Crew
90% Goal
80%
Linear (A Crew)
70%
60% Linear (Day Crew)
50% Linear (B Crew)
40%
30%
20%
10%
0%
e
6
4
1
8
6
3
23
30
13
20
27
11
18
25
15
22
29
13
20
27
ag
4/
5/
6/
6/
7/
8/
3/
3/
4/
4/
4/
5/
5/
5/
6/
6/
6/
7/
7/
7/
er
Av
AFE Presentation: Maintenance Metrics 25

26. Maintenance Council
Colors
Schedule Attainment
Weekly 2009
100%
50%
0% J J J J J F F F F M M M M A A A A A M M M M J J J J J J J J J A A A A
Actual 85.9% 88.4% 67.6%80.0% 89.8% 78.8% 83.8% 72.1% 80.0% 63.9% 68.8% 57.8% 82.0% 82.8% 76.9% 78.9% 75.9% 77.1% 83.9% 80.0% 82.6%83.9%
Goal 80.5% 80.5% 80.5% 80.5% 80.5% 81.0% 81.0% 81.0% 81.0% 81.0% 81.5% 81.5% 81.5% 82.0% 82.0% 82.0%82.0% 82.0% 82.5% 82.5% 82.5% 82.5% 83.0% 83.0% 83.0%83.0% 83.0% 83.5% 83.5% 83.5% 83.5% 84.0% 84.0% 84.0%84.0% 84.0%
AFE Presentation: Maintenance Metrics 26

27. Maintenance Council
Ascending vs Descending
Stock Outs Stock Outs
20 Jan Feb Mar Apr May Jun Jul Aug Sep Oct
20
15
15
10 Bearings
10 Bearings
5
5
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct 0
Safety Work Orders Safety Work Orders
% Complete % Not Done
100 50
80 40
60 30
40 20
20 10
0 0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
AFE Presentation: Maintenance Metrics 27

28. Maintenance Council
Dashboards
• Several charts on one publication
AFE Presentation: Maintenance Metrics 28

29. Maintenance Council
Types of Charts
• Line /Bar
– Most Straightforward
• Pie Chart
– Used to compare to total amounts
• Radar Chart
– Used to plot several non-competing numbers
AFE Presentation: Maintenance Metrics 29

30. Maintenance Council
Lists and Data
• Bad Actor Equipment
• Inventory items over $xxx
• Training by Employee
• Breakdowns avoided by PdM
• Number of trouble calls by Area
AFE Presentation: Maintenance Metrics 30

31. Maintenance Council
Effective Metrics
• Know your audience
– Show them something they care about
– Show them something they can effect
• Drive Results
– You get what you measure
– Do something with your information
• Present for effect
– Tell a story
– Make your impact quickly
AFE Presentation: Maintenance Metrics 31

32. Maintenance Council
Questions?
AFE Presentation: Maintenance Metrics 32