Making Preventive Maintenance Count: The Importance of PM KPIs
Jai Balachandran
Founder - MaintWiz CMMS | Asset Management | Plant Maintenance | TPM Digitalization | OEE | OT-IT Integration | industry 4.0 | SaaS Innovator
Preventive maintenance (PM) is a crucial part of any maintenance management program. It involves regularly scheduled inspections, cleaning, and repairs to equipment and machinery to prevent potential breakdowns and costly downtime. However, just implementing a preventive maintenance program is not enough. To truly make it count, you need to measure its effectiveness
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What are PM KPIs and Why are They Important?
?PM KPIs are metrics used to measure the success of your preventive maintenance program. They enable you to track and measure
PM KPIs, ?can help you identify trends and patterns in your maintenance data, such as identifying which assets require the most maintenance, which maintenance activities are most effective, and how much time and money you're spending on maintenance.
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Key PM KPIs to Measure
?There are several key PM KPIs that you should track when implementing a preventive maintenance program:
?1. PM Compliance
?PM Compliance measures the percentage of preventive maintenance work orders that are completed on time as scheduled. It's calculated by taking the number of completed PM work orders divided by the total number of scheduled PM work orders. By tracking PM Compliance, you can identify if your maintenance team is meeting your preventive maintenance goals, and if there are any areas for improvement in your maintenance program.
?2. PM Effectiveness
?PM Effectiveness measures the percentage of preventive maintenance activities that prevent equipment failure or identify potential problems before they occur. It's calculated by taking the number of PM work orders that prevent equipment failure divided by the total number of PM work orders. By tracking PM Effectiveness, you can identify which preventive maintenance activities are most effective in preventing equipment failure and which ones need improvement.
?3. Mean Time Between Failures (MTBF)
?MTBF measures the average time between equipment failures. It's calculated by taking the total operating time and dividing it by the number of failures. By tracking MTBF, you can identify equipment that's prone to failures and prioritize maintenance activities accordingly.
?4. Mean Time to Repair (MTTR)
?MTTR measures the average time it takes to repair equipment after a failure. It's calculated by taking the total downtime and dividing it by the number of repairs. By tracking MTTR, you can identify equipment that takes longer to repair and prioritize maintenance activities accordingly.
?5. Repeat Failures
?Repeat Failures measure the percentage of equipment that fails within a specified period after a previous repair. By tracking Repeat Failures, you can identify if there are any underlying issues that are not being addressed during maintenance activities, and if there are any trends that need to be addressed.
?6. Cost of Maintenance
?The Cost of Maintenance measures the total amount spent on maintenance activities, including labor, parts, and any other associated costs. Cost of maintenance can be sliced and diced to view to different perspectives - by maintenance type, by period, by equipment group etc. By analyzing the cost of maintenance, you can identify opportunities to reduce costs and improve efficiency.
?7. Overdoing PM
It is possible to overdo PM activities, which can result in unnecessary maintenance costs and downtime.?Evaluating equipment criticality and service levels required can provide right benchmarks. By comparing key availability, performance and other metrics against benchmarks, you can identify if you are performing too much maintenance and adjust your preventive maintenance program accordingly.
8. Breakdown since Last PM
?Breakdown since Last PM measures the time between the last preventive maintenance activity and the next equipment failure. By tracking Breakdown since Last PM, you can identify if the current preventive maintenance schedule is effective or if it needs to be adjusted to prevent future equipment failures.
9. MTTR / MTBF Comparison with Peer Equipment
?Comparing the MTTR and MTBF of equipment within the same group is important to identify any outliers. By comparing the MTTR and MTBF of peer equipment, you can identify which equipment is performing better or worse and identify any underlying issues that need to be addressed.
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How to Measure PM KPIs
?Measuring PM KPIs requires a well-planned approach. Here are some key steps to follow:
?1. Select the Right Metrics
?The first step is to select the right metrics to measure the success of your preventive maintenance program. The metrics you choose will depend on your specific goals and objectives, but PM Compliance, PM Effectiveness, MTBF, MTTR, Repeat Failures, Cost of Maintenance, and Breakdown since Last PM are some of the most commonly used PM KPIs.
?2. Standardize Formulas
?Standardizing the formulas used to calculate PM KPIs is important to ensure consistency across the organization. This will help you to compare performance across different departments, shifts, and equipment types. Having a standardized formula also simplifies data collection and makes it easier to compare data over time.
?3. Use a CMMS System
?A Computerized Maintenance Management System (CMMS) can help automate data collection and streamline the process of tracking PM KPIs. A CMMS can also generate reports and dashboards to help visualize your data and identify areas for improvement.
?4. Analytics and Dashboards
?Analytics and dashboards provide a way to visualize your PM KPI data and identify trends and patterns. They enable you to quickly identify issues and take corrective action. Analytics and dashboards can be integrated with your CMMS system, and can be accessed from any device with an internet connection, making it easy to stay on top of your maintenance program.
?5. Review KPIs Effectiveness
?Reviewing the effectiveness of your PM KPIs is important to ensure they are providing the insights you need to improve your maintenance program. You should review your PM KPIs on a regular basis and make adjustments as needed to improve their effectiveness.
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How Industry 4.0 Helps
?Industry 4.0 technologies such as the Internet of Things (IoT), Artificial Intelligence (AI), and Big Data Analytics can help improve your preventive maintenance program. IoT sensors can be installed on equipment to provide real-time data on its condition, allowing you to identify potential issues before they become a problem. AI algorithms can analyze maintenance data to identify patterns and predict equipment failures. Big Data Analytics can be used to process large amounts of data and identify trends and patterns that would be difficult to identify manually.
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Continuous Improvement
?Continuous improvement is key to the success of any preventive maintenance program. By measuring PM KPIs, you can identify areas for improvement and take corrective action. Regularly reviewing your PM KPIs and making adjustments to your maintenance program can help you optimize your preventive maintenance activities and maximize your return on investment
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?Measuring PM KPIs is crucial to the success of any preventive maintenance program. PM KPIs enable you to track and measure the effectiveness of your maintenance activities, identify areas for improvement, and make data-driven decisions. By selecting the right metrics, standardizing formulas, using a CMMS system, and leveraging analytics and dashboards, you can optimize your preventive maintenance program.
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