Surely one of your purposes for 2023 is to increase the efficiency and productivity of your factory and, above all, to reduce costs. To help you achieve your goal, in this article we highlight some industrial maintenance KPIs that you should keep an eye on.
To boost the efficiency and performance of a production plant, it is essential to have a good industrial maintenance plan. The management of this department is so important that it can determine the long-term success or failure of a factory.
It should not be forgotten that maintenance activities play a key role in ensuring the proper functioning of equipment, guaranteeing the quality of production, avoiding the dreaded stoppages in the manufacturing line and reducing unnecessary costs as much as possible.
At this point, how can a maintenance manager know whether or not he or she is doing a good job? As usual, the answer to this question lies in the data. Remember that it is impossible to optimize any process unless you have reliable, real-time information to guide your decisions.
Most important KPIs for industrial maintenance management
In previous articles we already talked about the qualities of a CMMS and the benefits this tool can bring to an industrial company, as well as the reasons why it is worth adopting a more proactive attitude and allocating more resources to boost preventive maintenance.
Now it is the turn of industrial maintenance KPIs. We have made a selection of five indicators that we consider indispensable. By monitoring them, organizations will be able to detect their main weaknesses and take appropriate actions for continuous improvement.
1. Mean time between failures (MTBF)
The mean time between failures (MTBF) measures the average time of equipment operation between breakdowns and/or stoppages. Calculated in hours, MTBF helps companies to know the availability of their equipment and to identify if they are experiencing operational problems.
Keeping track of the MTBF of each piece of equipment, especially those that operate continuously, is essential to effectively plan preventive maintenance activities and, as a result, increase their useful life and minimize the number of unscheduled shutdowns.
2. Mean time to repair (MTTR)
Mean time to repair (MTTR) is the average time it takes maintenance personnel to diagnose, repair and start up equipment after a breakdown.
Tracking this KPI helps companies improve their capacity and speed of response and reduce availability losses caused by repairs. In fact, minimizing the MTTR values of equipment is a step towards maximizing productivity in the factory.
3. Maintenance backlog
This indicator is an average expressed in hours that quantifies the time needed to perform all the pending maintenance operations: preventive, corrective, etc.
It is generally acceptable to have a certain backlog of work. Problems arise when the load of maintenance activities is unmanageable and neglected tasks end up causing more breakdowns and increasing downtime.
To effectively manage the backlog, it is necessary to have all maintenance work under control and to establish a task execution schedule according to criteria such as usage, failure rate or maintenance time and cost for each piece of equipment.
4. Planned Maintenance Percentage (PMP)
The planned maintenance percentage (PMP) is an indicator that describes the total amount of time spent on scheduled maintenance tasks.
It is recommended that around 85% of maintenance time should be spent on planned activities. If a company focuses its efforts on unscheduled or emergency tasks, its PMP will most likely be lower than recommended and they will have to implement improvement actions to reverse this situation.
5. Preventive Maintenance Compliance (PMC)
The preventive maintenance compliance (PMC) rate is a metric that expresses how many scheduled preventive maintenance tasks have been completed during a given period.
This KPI serves as a benchmark for evaluating the effectiveness of an organization’s preventive maintenance plans and indicates the extent to which these programs are being adhered to. A high rate is a good thing (and also means that the PMP and availability ratio will also be high). On the other hand, a PMC below 90% should be a cause for concern and it should also motivate us to review our preventive maintenance plans.