Reviews of the bill of materials for maintenance tasks can improve the planning data. Keeping an eye on the big picture will help to ensure that everyone is on the same page, knowing that the collective effort of every individual and department is leading to the achievement of the corporate business goals and performance. MPU = dollars spent on maintenance / production achieved. Using the wrong maintenance metrics—or worse yet none at all—can cause or contribute to problems like the following. Sometimes this global goal is expressed in terms … ... M-12/M-13 Automatic AC Transmission Outages Initiated by Failed Protection System Equipment / Automatic AC … The reliability scorecard is critical to capturing project benefits and should include the following types of measures: Transition – These are temporary project measures to indicate whether reliability changes are taking place. When measuring reliability, consideration must be given to the data contained in management reports. But you can't figure out where to start fixing your maintenance organization or how because you don't know where you're at. Monitoring the long-term trends will show whether these daily activities are having the desired effect on the performance and highlight where some tweaking is required. This could be due to things like breakdowns in equipment or a lack of availability of spares to execute the planned work. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). Warnings of pitfalls to avoid as part of the metrics process. Employees gripe. Sometimes this global goal is expressed in terms of profitability, sometimes in terms of revenue, sometimes in terms of production. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. Inherent Availability 5. While the availability of the faulty mixer may still be quite high if opera… Using MTTR, you can find the average time it takes your maintenance staff to reinstate a machine to its optimal working condition following a breakdown. However, it is possible to mask this indicator by cutting back on maintenance expenses in the short term only to incur major costs later when equipment starts to fail. Equipment fails. These KPIs can be used to directly influence the culture of an organization and direct action can often be taken in response to these indicators. 1 measure of reliability worldwide is mean time between failure." Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. The goal of a main-tenance and reliability program is to deliver a proper balance of maintenance activities — primarily those aimed at … As long the preventative maintenance tasks are properly defined and are truly beneficial to ensure that equipment does not fail prematurely, then the completion of these tasks as per the plan will cause the long-term reliability trends to show improvement. Another major trend indicator is the financial KPI of Maintenance Cost per unit Production. For the unfamiliar, mean time between failures is the average length of operating time between one failure and the next of an asset. As a hypothetical example, imagine a faulty mechanical mixer. Establishing metrics is essential for demonstrating the benefits of maintenance and reliability best practices. Reliability = V x 100 W The frequency with which the machine breaks down and disrupts production Data Although we may be able to achieve step changes in the behavior of a maintenance and production team, the effect of these changes on the overall reliability and performance of the equipment can only be measured as a trend over time. Steady State Availability 4. For utility companies, reliability means success. There are loads of metrics that are relevant and important to utilities, but three, in particular, are crucial for tracking reliability success. MPU is a simple ratio which can be measured against benchmarks for each specific industry. Failure rate is the number of failures per 1000 hours of operation. One of the challenges of building and maintaining an effective reliability and maintenance strategy for any manufacturing organization is the task of sifting through the many proposed measures of success to come up with a KPI matrix that is relevant, easy to understand and actually drives the behaviors and performance in the right direction. Reliability measures the probability that the system will perform without failure over a specified interval under specified conditions. You can use our product to measure the performance metrics of your equipment and keep track of your assets more efficiently! However, new technology only enables an ineffective maintenance program to be more efficient at being ineffective. The financial impact of unexpected equipment failure can be costly, as AK Steel Corp. shared recently. If this doesn’t happen, then the short-term KPIs should be reviewed to ensure that the right actions and behaviors are being measured and controlled and changes should be made as necessary. Every part of the organization is serving the same corporate goals and objectives even though each part is playing a vastly different role and carries different responsibilities. However, in most cases, the exponential distribution is used, and a single value, the mean time to failure (MTTF) for non-restorable systems, or mean time between failures (MTBF for restorable systems are used). Can we control both long-term trends and short-term changes in culture and behavior? Here you can focus on three main areas for which you can define additional KPIs: assets, operational and customers. Industry Data. How should we respond to changes in the KPI we are measuring? It is important as a reliability and maintenance professional to focus daily attention on the short-term KPIs in order to drive the behavior and cultural change that is needed in an organization. Everyone who has worked in a complex organizational structure like that required in manufacturing knows that there is a need to constantly fight against the tendency towards thinking in silos. It encompasses availability, performance, and quality, and when used correctly is removing waste. Specific metrics for measuring effectiveness in key areas such as maintenance planning and scheduling and MRO storerooms and material management. While general metrics work well for gauging the overall performance of any business, equipment rental firms need to go beyond general metrics to get the most accurate results. It's necessary to change their opinion by changing your perspective. Since MTBF indicates the operating time of an asset, it is a metric that is closely related to the calculation of the reliability of plant and equipment, as much as metrics used to calculate the operating availability of the machine, in particular OEE (Overall Equipment Effectiveness). People and Processes, Inc.P.O. Reliability uses many metrics for evaluating equipment and systems. Reliability may be Departments throughout your organization, including Maintenance, Operations, Materials Management, Planning and Scheduling and Purchasing, all play vital roles and contribute to the company's bottom line but most are unmeasured. The Society for Maintenance and Reliability Professionals (SMRP), developed standard definitions for metrics used in industry. Corporate Metrics. The original metric, Mission Reliability, answered the question of figure 4. Is the probability that an asset, item, or unit will perform its prescribed duty without failure for a given time in a specified environment. Maintenance and reliability managers must have metrics in place to identify needs for improvement. Everything goes wrong. Learn how digital permitting can reduce hazardous incidents, mitigate unsafe isolations and sub-par risk assessments, and ensure regulatory compliance. Taxonomy Definitions. And, how can project managers ensure their teams accomplish those reliability goals? Reliability Consultant, Ivara Ron Thomas Director of Reliability Practices, Dofasco ... relate to manufacturing metrics. The last type of KPI that should be considered when building a reliability and maintenance program and measuring the performance is a KPI that measures immediate impact. The classification of availability is somewhat flexible and is largely based on the types of downtimes used in the computation and on the relationship with time (i.e., the span of time to which the availability refers). I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be on continuous improvement. Simply put availability is a measure of the % of time the equipment is in an operable state while reliability is a measure of how long the item performs its intended function. © 2020 Prometheus Group All Rights Reserved. If our maintenance and reliability strategies are effective and are solving the problems that cause failures in our equipment, this should show a continuous upward trend, which stabilizes at industry benchmark levels. In other words, reliability of a system will be high at its initial state of operation and gradually reduce to its lowest magnitude over time. Only by tracking these critical KPIs can an enterprise maximize uptime and keep disruptions to a minimum. An organization that insists on the completion of these day-to-day routines will, therefore, drive the overall performance upwards and will see the impact on the long-term trends and the achievement of the big picture KPIs. Theoretically, defects can be introduced into equipment at each of the six main phases of its life cycle: Design… When objectives are reached, you can remove these measures from the scorecard and add new transition measures. Once these short-term indicators are under control, the long-term trends should move in the right direction too. As a result, there are a number of different classifications of availability, including: 1. ISPM helps asset-intensive industries improve equipment availability and minimize hazards with high-quality equipment reliability data. MTTR, also referred to as maintainability measures the ability to do maintenance to keep or restore equipment to a specified operating condition. One example of a corporate-level KPI is the measure of how well the manufacturing facility performs in terms of meeting the planned production that is laid out for it by the business. PSA can be calculated as a percentage and should be as close to 100% as possible. Data Quality. So, which metrics should utility executives care about? Allocating equipment and inventory to selected employees or teams; Predicting the budget for future equipment and maintenance costs; Five metrics you can use to evaluate Asset Reliability at your plant are: 1. Average Uptime Availability (or Mean Availability) 3. Another metric that relates to the duration that an equipment operates is reliability. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. Availability, also known as operational availability, is expressed as the percentage of time that an asset is operating compared to its total scheduled operation time. Below are some practical steps to help facilitate a discussion on the right KPIs and approach for your organization. You know maintenance needs better software and you’ve found the perfect solution. Reliability must be sufficient to support the warfighting capability needed in its expected operating environment. For example, a radical improvement in the management of lubricating oils for rotating equipment can be achieved with the introduction of a new system of sampling, testing, and flushing. There are literally hundreds of KPIs published that we are told should help us to measure and control our manufacturing, reliability and maintenance performance. PMSC can also be calculated as a percentage and should be as close to 100% as possible. Planned maintenance percentage (PPC) This metrics represents the percentage of time spent on … It is calculated by dividing a specified period of operating hours by the number of failures. Adequate Level of Reliability (ALR) Metrics. 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