How do you measure and report the performance and impact of your maintenance management activities?

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Maintenance management is the process of planning, organizing, and controlling the activities related to the upkeep and repair of physical assets, such as equipment, buildings, and infrastructure. It is essential for ensuring the reliability, availability, and safety of these assets, as well as optimizing their life cycle costs and performance. But how do you measure and report the results and impact of your maintenance management activities? In this article, we will explore some of the key indicators and methods that can help you evaluate and communicate your maintenance management performance and outcomes.

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Shadi Abdelkareem aleryani

+26Million Impressions | +45kFollower |Professional Electrical Engineering at OMV

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Rory McLaren

Founder/Director/Teacher/Author/Red Seal
Jonathan Steven Bare?o Gonzalez

Ingeniero Mecatronico, Especialista en Gerencia de Mantenimiento y regulación y eficiencia energética de energías…

1 Maintenance objectives and metrics

Measuring and reporting your maintenance management performance and impact starts with defining your maintenance objectives and metrics. These goals and measures should align with your organizational strategy and vision, and reflect the value and benefits of your maintenance activities. For instance, you can measure downtime and availability with indicators such as mean time between failures (MTBF), mean time to repair (MTTR), or availability ratio. Additionally, you can measure productivity and efficiency with overall equipment effectiveness (OEE), maintenance productivity ratio, or maintenance cost per unit of output. Quality and safety can be measured by indicators such as defect rate, rework rate, or safety incidents. Finally, asset life and costs can be measured by asset utilization, asset turnover, or maintenance cost per asset.

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Rory McLaren

Founder/Director/Teacher/Author/Red Seal
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That's simple! Look at the machine availability, and reason for downtime. If it's a breakdown that halts production it's poor maintenance, which is defined as "maintenance management by crisis." This is the status quo. If its scheduled downtime, it's defined as "planned maintenance," which means the maintenance manager is doing his or her job. If the maintenance managers are managing the maintenance of hydraulic systems, you can bet your bottom dollar that no hydraulic component is being removed from service until it suffers a catastrophic failure. Forty years ago 90% to 95% of hydraulic components failures were related to contamination. Forty years on and the numbers haven't changed compliments of maintenance management.

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Reyniw Oliveira

Líder em Seguran?a e Performance no Setor Elétrico | Supervisor For?a e Energia EFC | MBA Gest?o de Pessoas | Esp. Gest?o de Manuten??o e Seguran?a | LSS Green Belt | Minera??o | SFPC | SEP | Scrum Master | Energia
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Para medir e relatar o desempenho das atividades de manuten??o, utilizo indicadores específicos como o tempo médio entre falhas (MTBF), e o tempo médio de reparo (MTTR). Esses KPIs oferecem insights sobre a eficiência operacional e a confiabilidade dos ativos. Também, analiso o custo total de manuten??o, considerando tanto os custos preventivos quanto os corretivos. Isso proporciona uma vis?o abrangente do investimento em manuten??o versus a eficácia na preven??o de falhas. Quanto ao impacto das atividades de manuten??o, observo o aumento da vida útil dos equipamentos, a redu??o de paradas n?o programadas e a melhoria geral na confiabilidade operacional. Esses resultados s?o fundamentais para avaliar o sucesso das estratégias de manuten??o.

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Sumit Gautam

Maintenance Lead
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Measuring and reporting the performance and impact of maintenance management activities requires a comprehensive approach involving KPIs, maintenance tracking systems, RCM principles, RCA, regular reporting, feedback mechanisms, benchmarking, and a commitment to continuous improvement. Below are the steps 1.Key Performance Indicators. 2.Maintenance Tracking System. 3.Reliability-Centered Maintenance (RCM). 4.Root Cause Analysis (RCA). 5.Feedback Mechanism from all stakeholders 6.Benchmarking and Best Practices. 7.Adaptation and Continuous Improvement.

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Khalid Waleed

Preventive Maintenance Manager / KCML - Lafarge Iraq
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The best tool is to use a comprehensive CMMS tools that give you the ability to do the on going tracking for inspection program effectiveness, planning accuracy and scheduling compliance, those leading KPI will reflect the final shape of your maintenance management lagging Kpi like MTBF , NAI , OCR and maintenance cost .

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Renato Lopes

Head de Manuten??o | Gerente de Manuten??o Sr | Gest?o de Pessoas | Lean Maintenance | TPM | RCM | 5S | Melhoria Contínua | Manuten??o 4.0 | Gest?o de projetos
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é de extrema importancia que toda a equipe esteja alinhada com as metas do indicadores de desempenho. Um quadro de gest?o visual apoia o processo para que todos entendam o momento e estejam engajados no rumo tra?ado. Importante que os indicadores sejam interpretados rapidamente e reflitam a realidade do setor!

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2 Maintenance data collection and analysis

The second step to measure and report your maintenance management performance and impact is to collect and analyze your maintenance data. This involves gathering, processing, and interpreting information related to your maintenance activities, such as work orders, inspections, repairs, costs, and outcomes. Various tools and methods can be used for this purpose, such as maintenance management software which helps manage operations and provides dashboards, charts, and reports on performance trends. Additionally, maintenance audits and inspections are periodic assessments that evaluate processes, practices, standards, asset condition and performance. Maintenance benchmarking and comparison is also important for comparing your performance with other similar organizations or industry standards in order to identify best practices and areas for improvement.

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Shadi Abdelkareem aleryani

+26Million Impressions | +45kFollower |Professional Electrical Engineering at OMV
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MTTF, MTBF, MTTR, the number of unplanned breakdowns, corrected WOs, completed WOs, overdue WOs, completed late WOs, and the most expensive equipment are all great places to start. Since effective management is the foundation of optimization, measure it to manage it. A robust planning tool is necessary in order to measure, control, and optimize reliability operations. Comprehensive improvement is made possible by CMMS, which assists with crucial and effective activities including organizing, planning, and storing historical data. SAP software is, in my opinion, a really useful tool. Data is extracted and analyzed once a month. Finally, a dashboard website display and report sharing are used to share KPI with the team and management.

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Jonathan Steven Bare?o Gonzalez

Ingeniero Mecatronico, Especialista en Gerencia de Mantenimiento y regulación y eficiencia energética de energías renovables.
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Data,Análisis, medición ,objetivos, control y mejora continua. Creo que antes de medir la gestión de mantenibilidad de los activos,debemos pensar primero cómo la gestionamos de manera eficiente y segura la información de campo. Hoy en día existen infinidad de indicadores de mantenibilidad a nivel global , pero el éxito de una gestión adecuada de mantenimiento es la orientación a la confiabilidad de datos, análisis,plantearnos objetivos y la mejora continua de lo que medimos que muy seguramente nos llevará a plantearnos a diario cada indicador en que nos puede maximizar la eficiencia operacional de la industria donde nos desempe?emos. Frese “ lo que no se mide, no se controla y lo que no se controla,no mejora”

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Glyn Gannon MBA C Eng MIET

Former Engineering Maintenance Manager at James Cropper plc
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MTTR, MTBF, %Downtime, Safety incidents- Accidents, Dangerous Occurrences, Potential Hazards, Budget Labour and Materials, Capital Project % complete / on track. Staff turnover, Apprentice Performance, Work Backlog in the CMMS. Shutdown work completion v plan. Number of unplanned Work Orders / jobs. Number of Material / Spares Stock outs ( Availability ), % completion of maintenance routines. Power plant / site services availability. Power, Steam, Gas, Water,Compressed Air, % Condensate Returns. Energy savings ……

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Dwayne T.

Reliability Engineer at Wonderbrands | Driving Manufacturing Efficiency
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In my experience the metrics used need to be clear and easy to understand. PM Completion rates alongside Mechanical Downtime is powerful…the relationship between these two is easy to see and can motivate technicians. MTBF is a useful metric as well…as measure of reliability, it is a great motivator as well. Maintenance/reliability departments need to see how what they do makes an impact…lose sight of impact, and loss of engagement is soon to follow.

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Mustapha. MEZGHRANI

Sr / Maintenance & Project Manager. Digitalisation Fonction Maintenance , IoT/SCADA/GMAO. Activités Maintenance Sous ISO / SMI, 9001-14001-45001-26000 / RSE. Expertises/ énergies, Eaux, Agroalimentaires, & Emballage CO.
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Si nous avons atteint le niveau de collecte des données issues de l’activité maintenance, c’est que nous avons compris et ma?triser les paramètres : l’Amdec, Mttr, Mtbf, Trs, etc.. qui nous permettent non seulement de mesurer mais aussi d’améliorer d’avantage la fiabilité, et la performance du bon modèle choisi de management de la maintenance. Et à ce sujet de modèle ou politique choisi, les grandes multinationales (500) se sont déjà bien engagées sur d’autres horizons et autres nouveaux programmes aux concepts de l’industrie IV.0, V.0.. et ou l’ère du préventif n’est plus d’actualité, révolu. Très prochainement nous aborderons le sujet de la maintenance dite par la surveillance, ou communément appelée prédictive ou encore le CBM.

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3 Maintenance reporting and communication

The third step to measure and report your maintenance management performance and impact is to report and communicate your maintenance results and outcomes. This involves presenting and sharing your maintenance data, metrics, and analysis with stakeholders such as management, customers, employees, and regulators. Various tools can be used for this purpose, including maintenance reports, presentations, and dashboards. Maintenance reports are written documents summarizing performance and impact such as costs, savings, quality, safety, and reliability. These may include recommendations, action plans, and feedback for improvement. Maintenance presentations are oral or visual presentations showcasing performance and impact such as achievements, challenges, and best practices. They may include graphs, charts, tables, or images to illustrate data and analysis. Finally, maintenance dashboards are interactive displays showing key performance indicators (KPIs), trends, and alerts. These allow users to drill down or filter for customization of data and analysis. Different formats and styles can be used for each of these tools.

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Rishi Kumar

JIPM certified TPM Instructor: Consultant, Corporate Trainer, Speaker
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Maintenance Management is about People. Process, and System. There are a few pre-requisites: Maintenance is an equal partner with production. During decision for procurement of new Equipment, inputs based on MP Design, FMEA, RCM, Life Cycle Studies. A Predictive Maintenance program exists Personnel involved in the Predictive Maintenance program have received appropriate training and certifications. Competency level of crew involved in predictive maintenance is subject to regular review Operations, engineering and maintenance people are all involved in RCA. Root Cause actions are completed on time and issues do not re-occur There is a system of periodic assessment of all Physical structures including Equipment structures.

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Daniel Fatel

Gerente de Produ??o e Manuten??o | Supervisor de Manuten??o e Produ??o | Six Sigma - Black Belt
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Relatórios eficientes e feedbacks constantes com a equipe s?o o pontos mais importantes para ter uma manuten??o eficiente. A comunica??o e alinhamento dos objetos com a equipe é principal ponto, pois com uma equipe alinhada com o objetivo os relatórios feedback tem mais chances de serem assertivos.

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Jose Duran

Maintenance Manager & Reliability Professional & Profesional de mantenimiento y confiabilidad CMRP / Especialista. MSc Project Managment.
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En mi experiencia es fundamental en esta fase mantener informado del rendimiento y el impacto de la gestión, al mismo personal del equipo de trabajo de mantenimiento. Que se cumplió? Que no? Cuáles fueron las causas? Cuál es el plan? Como impacta el trabajo de cada uno de los miembros del equipo en los resultados del indicador y por último es obtener el feedback del equipo (las propuestas e iniciativas de valor), evaluarlas, desarrollar el plan de acción, reconocer y promover los buenos resultados.

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Jonathan Steven Bare?o Gonzalez

Ingeniero Mecatronico, Especialista en Gerencia de Mantenimiento y regulación y eficiencia energética de energías renovables.
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Para medir y comunicar el rendimiento y el impacto de las actividades de gestión de mantenimiento de forma efectiva: 1. Establecer KPIs relevantes que generen valor 2. Utilizar software para la adquisición y administración de datos. 3. Analizar resultados y define acciones. 4. Comunicar con un interfaz gráfica y datos simplificados y claros. 5. Destacar lo logros y dar recomendaciones en un resumen ejecutivo. 6. Utilizar un lenguaje claro y evitar tanto tecnicismos para que sea de fácil interpretación creando sinergias con actores no especialistas en la definición de mantenimiento.

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R K Mohapatra

Ex G M Transformer Design BHEL Director AARAMCO Transformer Consultancy
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Impact of Maintenance management can be known by comparing MTBF . The other indicative parameters are loss of production and the reducing life of equipment leading to replacement cost in terms higher depreciation .

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4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ramzi Aljilany

Senior Instrument and Control Technician at OMV | +38K Followers | +17M Impressions
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Certainly! Here are some points to consider when measuring and reporting the performance and impact of maintenance management activities: 1. Key Performance Indicators (KPIs) 2. Work Order Completion 3. Asset Performance 4. Compliance and Safety 5. Cost Analysis 6. Downtime Analysis 7. Customer Satisfaction 8. Root Cause Analysis 9. Trend Analysis 10. Reporting So considering these points, you can effectively measure and report the performance and impact of your maintenance management activities.

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Nathan Wright

I develop authentic, transformational leaders who create a clear vision and strategy to improve organizational efficiency.
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I agree with you Rishi. The key to robust maintenance is the proper tools implemented by qualified individuals. Doing anything for the sake of doing it is a waste of time. Only spend your efforts in areas where you will use the data to drive actionable efforts. I am not a fan of three-letter acronyms and the programs they are associated with, but if you do not know what to do or where to start, they may provide guidance.

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John Yolton

Principal at FOG Group
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Consider this: Much of your improvement attempts may be confronting long established 'past practices', many of which are cultural and deeply embedded in the psyche of the tribe. How are you going to measure progress with the cultural aspects? What KPIs exist for these 'soft' issues? And how do you measure them?

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Alek Z.

Supervisor Facilities at Thermo Fisher Scientific
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Effective lubrication management is crucial for maintaining the efficiency and reliability of machinery. Organizations can prevent many common equipment failures caused by inadequate lubrication by improving their lubrication practices. This involves thoroughly training maintenance personnel in the correct lubrication techniques and scheduling. Consistent application and vigilant monitoring of lubrication practices can significantly enhance equipment performance and extend its operational life, ultimately reducing breakdowns and maintenance costs.

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Pourya Azar
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Benchmark against industry standards to set targets and identify improvement areas. Involve all stakeholders for better collaboration and buy-in. Invest in training for the maintenance team to enhance skills. Utilize advanced technologies like predictive maintenance and machine learning for more accurate analysis and effective strategies.

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How do you measure and report the performance and impact of your maintenance management activities?

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1 Maintenance objectives and metrics

2 Maintenance data collection and analysis

3 Maintenance reporting and communication

4 Here’s what else to consider

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