Doug Pillars is seeking a comprehensive "best practice" matrix for overall maintenance performance, including key metrics such as 80% preventive maintenance and 100% of all work being tracked through a CMMS system. If anyone can provide me with this essential tool that we use to measure success, it would be greatly appreciated. I had a copy of it but unfortunately lost it during a recent computer migration. Thank you in advance. - Doug Pillars, Maintenance/Reliability Engineer at Nissan.
For those seeking a matrix for maintenance benchmarking, a valuable resource can be found on MaintenanceBenchmarking.com in John Mitchell's book "Physical Asset Management." Explore this benchmarking tool along with other projects on the site for valuable insights and best practices. Best of luck in your endeavors! - Terry O'Hanlon, CMRP.
Doug, I understand your perspective on the importance of integrating 100% of jobs into the CMMS system. However, is there a solid justification for maintaining 80% Preventive Maintenance? What makes Preventive Maintenance superior to Breakdown Maintenance in cases where failure consequences are minimal or non-existent? If you have an ample amount of spare capacity or utilize intermediate buffer storage, it may be difficult to justify implementing Preventive Maintenance. On the other hand, if you can accurately predict the degradation process, Condition-based Predictive Maintenance can prove to be highly beneficial. The decision regarding the ratio of Preventive Maintenance to Total work should be based on the potential consequences of failure, which can only be assessed by evaluating the specific configuration and conditions in your facility. Our main objective should be minimizing total risk, which may not necessarily align with maximizing Preventive Maintenance efforts. V.Narayan.
When comparing reactionary work orders to planned maintenance tasks (such as PM and PdM), the objective is to ensure that the number of reactive work orders is kept below 20%. Reactive work orders refer to jobs that are typically carried out without prior planning, usually within a week's time frame. This type of work often leads to unexpected overtime and the need for on-the-spot planning. For example, let's consider a scenario where the burner fuel oil pressure is gradually dropping over time. The minimum pressure required for proper fuel atomization is 150 psi, with the normal range being 300-350 psi. At around 250 psi, maintenance is alerted and a shutdown is scheduled. Possible causes are identified (such as issues with the burner tip, fuel pump, or controller), preliminary checks are conducted, and the situation is monitored closely (planned scenario). On the other hand, imagine a situation where maintenance staff arrives on a Monday morning to discover that an emergency shutdown occurred over the weekend, resulting in the furnace being full of oil (reactive scenario). This type of situation does not fall under the category of Preventive Maintenance, yet it is a common occurrence in many facilities.
Apologies, but the objective is to have fewer than 20% of work orders be reactive.
quote: In a successful maintenance strategy, the target is to keep reactive work orders below 20%. While high consequence failures may warrant preventive maintenance or predictive maintenance activities, there are also minor failures that have little to no impact on safety or production. If spare equipment is in place, the failure of a piece of equipment should not disrupt operations. Apart from basic lubrication and minimal condition monitoring, it can be argued that no additional maintenance is necessary, and running equipment to failure is acceptable unless it leads to significant internal damage. The threshold of 20% for reactive work orders is not a universal rule and can vary depending on the specific situation. It is important to assess each case individually to determine the most effective maintenance approach. Any other method would be suboptimal. V.Narayan.
Hi Doug, sorry to hear about your lost file! I have a matrix in place at my company, although it's customized to our specific needs. But I'm more than happy to share it as a lever for your own version. I'd say the operative metrics we track besides those already mentioned are downtime percentage, repair time averages, cost per repair, and we also add metrics related to safety incidents. Every company has unique needs, so you might find it helpful to tinker with our matrix and see where it gets you. Will send it to you in a private message!
Hi Doug, I completely understand your situation, those computer migrations can be tricky. As far as comprehensive matrices, our organization has found that a simplistic, clear-cut approach is usually the most effective for maintenance performance. We predominantly utilize Return on Net Assets (RONA) and Overall Equipment Efficiency (OEE) as our chief indicators. Other KPIs to consider can include Maintenance Cost as a % of Replacement Asset Value (RAV), Schedule Compliance, and Downtime. However, remember that the "best" practice for any operation is often unique to that operation's specific circumstances and needs. Hope this helps!
Hi Doug! I totally understand the struggle with losing important tools during tech transitions—it's the worst! While I don’t have a comprehensive matrix to share, I recommend focusing on breaking down your maintenance goals into clear categories like preventive, predictive, and reactive metrics. It may also help to include asset criticality ratings and downtime impacts in your tracking. If you want, I can share some examples of metrics we've implemented successfully that blend with a CMMS framework. Let me know if that sounds good!
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
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Answer: Answer: Key metrics for measuring overall maintenance performance may include factors such as the percentage of preventive maintenance tasks completed, the percentage of work tracked through a Computerized Maintenance Management System (CMMS), equipment uptime, maintenance costs as a percentage of asset value, and mean time to repair (MTTR).
Answer: Answer: Preventive maintenance plays a crucial role in overall maintenance performance as it helps in reducing unplanned downtime, extending equipment lifespan, improving reliability, and optimizing maintenance schedules.
Answer: Answer: Tracking all maintenance work through a Computerized Maintenance Management System (CMMS) provides benefits such as improved visibility into maintenance activities, better resource allocation, historical data for analysis and decision-making, and streamlined communication among maintenance teams.
Answer: Answer: Organizations can measure the success of their maintenance performance by analyzing key performance indicators (KPIs) such as equipment uptime, maintenance costs, mean time between failures (MTBF), compliance with preventive maintenance schedules, and overall equipment effectiveness (OEE).
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