Demonstrating how your preventive maintenance program is achieving its goals and objectives requires tracking and analyzing metrics that reflect the quality, efficiency, and reliability of your activities. Common KPIs for preventive maintenance effectiveness include preventive maintenance compliance, mean time between failures (MTBF), mean time to repair (MTTR), availability, and cost of preventive maintenance. Preventive maintenance compliance looks at the percentage of scheduled tasks completed on time and according to standards, while MTBF measures the average time between two consecutive failures of a system or component. MTTR looks at the average time it takes to restore a system or component to normal operating condition after a failure, and availability measures the percentage of time a system or component is ready to perform its intended function. Lastly, cost of preventive maintenance looks at the total amount of money spent on activities such as labor, materials, tools, and overhead.
KPIs for Preventive maintenance effectiveness are: * Increased MTBF *Mean Time to Repair * Spares consumption * Check sheet and Checklist fulfillment *Production vs Processing cost *Reduction in Capex case *Reduction in Opex cases *Inventory management * Safe inventory level * Equipment Integrity *Equipment reliability *Availability of Standby These all above comprising factors indicates and analyze the effectiveness of robust Preventive Maintenance as per Checklist and strict compliance to designed scheduled either hourly/time based or Yearly/Monthly based as per Equipment historic record and condition monitoring.
"MTBF" Should include on-hand parts and stocking of long turnaround delivery items. "MTTR" This section should focus on qualified staffing and training for the inevitable failure, because this is the ultimate figure that determines the cost of any maintenance.
1) Maintenance Compliance Rate: Percentage of scheduled maintenance tasks completed on time. 2) Mean Time to Repair (MTTR): Average time taken to repair equipment after failure. 3) Mean Time Between Failures (MTBF): Average time between equipment failures. 4) Scheduled Maintenance Percentage: Proportion of preventive vs. reactive maintenance. 5) Downtime Reduction: Decrease in equipment downtime due to maintenance actions. 6) Work Order Cycle Time: Time from maintenance request to work order completion. 7) Cost Savings: Reduction in costs due to effective preventive maintenance. 8) Employee Satisfaction: Staff satisfaction with communication and workflows. 9) Audit and Compliance Rate: Adherence to regulations through reporting.
Big Thanks to linkedin, i saw this in my linkedin feed and search for this here is some KPIs i found... *Work Order Completion Time*: Tracks the average time to finish preventive maintenance work orders, highlighting process efficiency.*Equipment Availability*: Measures critical equipment availability post-maintenance, reflecting positive impacts on uptime. *Maintenance Backlog* Monitors pending tasks versus scheduled tasks to identify resource constraints or inefficiencies.*Cost of Preventive Maintenance*: Analyzes overall maintenance costs, justified by reduced downtime and expenses.*Technician Training and Certification*: Monitors the percentage of well-trained, certified technicians, crucial for effective maintenance.
KPIs provide a comprehensive view of program performance. To further enhance this approach, consider incorporating leading indicators like early fault detection rates or predictive maintenance accuracy. These can offer insights into the program's proactive capabilities, helping to identify potential issues before they escalate. Additionally, emphasize the correlation between preventive maintenance efforts and overall equipment reliability, highlighting the program's strategic impact on minimizing unplanned downtime and optimizing asset lifecycle. This holistic perspective ensures a well-rounded evaluation of preventive maintenance success.
An important part of preventive maintenance communication and reporting is demonstrating how the program is contributing to the performance and value of the organization. To do this, track and analyze metrics that reflect the outcomes and benefits of preventive maintenance activities. Common KPIs include Return on Preventive Maintenance Investment (ROMI), which measures savings or profit generated by the program in relation to its cost; downtime reduction, which shows how much productivity and availability are improved; quality improvement, which indicates customer satisfaction and reputation; and risk mitigation, which reveals how much assets, employees, customers, and environment are being protected from damage, injury, liability, or compliance issues.
Impact of good Preventive Maintenance plan and execution, surely ensure the integrity and reliability of Plant and Equipment with smooth operation of plant to optimal production and minimize downtime and mitigate the production losses due to any repair/maintenance and catastrophic unforeseen failure of Equipment resulting in down of Whole complex or Process Unit which may disturbed the Quarterly or Annually Fixed target. Also impact on overall condition / health of company asset and worker easiness and reduction of stress level and lead to good working environment
Safety should be at the forefront of planning any PM KPIs, and also training of the team to become competent. Without these, the team will not feel as confident or competent enough to carry out the plan no matter how great of a plan it is.
Tracking KPIs like Return on Preventive Maintenance Investment (ROMI), downtime reduction, quality improvement, and risk mitigation provides a comprehensive view of the program's impact. These metrics not only quantify cost-effectiveness but also demonstrate improvements in productivity, customer satisfaction, and overall risk management. This transparent approach fosters a deeper understanding of the preventive maintenance program's value and facilitates informed decision-making at both operational and strategic levels.
Important KPI measurements for a PM system include several key components. -Measure the on time completion rate based upon when due to complete. Information key in reporting if your staffing levels can keep up with tasks. Late tasks will lead to failures. -Actual time to complete based upon estimated time to complete. Did the task meet expectations and were there any additional issues. Were follow up tasks created. What percentage of PM’s have follow up tasks created. Sign your PM might not be sufficient. Electronic PM systems that can be updated and viewed on the floor through a handheld tablet are your best options. Allows for easily updated issues, videos on how to perform PM, and real time updates.
To effectively communicate and report your preventive maintenance KPIs, you need to follow some best practices and principles that will help you present your data clearly, accurately, and persuasively. Good data quality is essential to make sure your data is complete, accurate, consistent, relevant, and timely. Data visualization helps to highlight trends, patterns, comparisons, or relationships in your data. Data storytelling enables you to engage your audience and connect your data to their needs or interests. And data feedback helps you improve your data quality, visualization, storytelling, and address any gaps or issues in your communication and reporting.
KPIs for preventive maintenance communication and reporting include the timeliness of reports, clarity of communication, frequency of updates, and issue resolution time. They also encompass stakeholder engagement, accuracy of information, and the completion rate of follow-up actions. These KPIs ensure that maintenance activities are effectively communicated and reported, leading to timely and accurate decision-making.
I would further stress the importance of tailoring your communication to your audience. Understanding the specific needs and interests of stakeholders allows you to present KPIs in a way that resonates with them. Additionally, consider incorporating real-time reporting tools to provide up-to-the-minute insights, fostering proactive decision-making. Regularly solicit feedback from stakeholders to ensure ongoing relevance and effectiveness in your communication strategy. By aligning data communication with audience expectations and leveraging real-time reporting, you enhance the impact of preventive maintenance KPI reporting.
Using preventive maintenance KPIs can help you monitor, evaluate, and improve your preventive maintenance program and its outcomes. To achieve the best results, you need to define your goals and objectives, select your KPIs carefully, collect and analyze your data systematically, communicate and report your data effectively, and review and update your KPIs regularly. When defining goals and objectives, you should make sure they are SMART (specific, measurable, achievable, realistic, and time-bound) and aligned with your organizational vision, mission, values, and strategies. When selecting KPIs, you should focus on the ones that are most important and meaningful for your organization and stakeholders. You should use appropriate tools and techniques to process and analyze data from various sources and systems. When communicating data, you should tailor it to the audience and purpose while using clear language with visual aids. Finally, you should monitor and evaluate KPIs periodically to identify any gaps or areas for improvement in your preventive maintenance program.
- L’utilisation d’indicateurs de performance clés de maintenance préventive permettent de mettre en place des mesures en cas d'ecart des objectifs, d'identifier les causes.
Need to consider the safety of the equipment and working personnel to ensure the effectiveness of the preventive maintenance
The challenge is to keep a balance between invested time (money) and potential cost avoidance. The key is to prioritize the criticality of the equipment and set the tasks accordingly. At the end of the day maintenance is the cost to the business and the time and resources have to be managed wisely.
It is important that a company understands that preventing maintenance, requires maintenance. With a proven practice of complete overhaul prevention maintenance. You develop the complex knowledge otherwise unseen by assembled equipment. It also develops a key component in recovery by providing experience with the equipment and its particular needs. As well as speed and confidence in repairs.