Module Objectives • Understand Key Measures For Maintenance Performance (MP) • Learn how to use these MP • Learn about Techniques for Continuous Improvement • Understand the elements of maintenance benchmarking Duffuaa
Measures Of Performance • Input Measures Primarily Cost Measures • Output measures • Within The System Measures • Maintenance Indices Duffuaa
Input Measures • Input Measures are Mostly Related To Cost • Labor : Cost of trades, semi-skilled etc • Materials • Contracts • Shop Service • Equipment Rentals • Maintenance Overhead • Company Overhead Duffuaa
Output Measures • Availability : Measure of Uptime • A = S-d/S * 100% , Where • A = availability • S = scheduled production time • d = downtime in days Duffuaa
Output Measures • Reliability : Mean-time-between-failure • MTBF = S-d/f , f is number of failures • Mean Time To Repair: Measure of Duration of Repair • MTTR = d/f • Utilization = Scheduled Time/C T • CT = Calendar Time Duffuaa
Output Measures • Process Rate (PR) : Measure of the Equipment Cycle Time in The Process • PR = Ideal Cycle Time/Actual Cycle time • Quality Rate (QR) : Measure of equipment Precision • Total Produced - Rejected/Downgrades/ Total • Overall equipment Effectiveness • OEE = A* PR *QR Duffuaa
Example • Suppose We have An Operation Scheduled To Operate For 31 Days. It has three failures. The Failures Duration Are For 2, 1 And 3 Days. Compute Availability, Percentage Down Time ( PDT) , MTBF and MTTR Duffuaa
Solution • A = (31-6)/31 * 100 = 80.6% • PDT = 100 - 80.6 = 19.4 • MTBF = (31 - 6)/3 = 8.33 • MTTR = Down Time From Failures/Number of Failure • = 6/3 = 2 days Duffuaa
Problem • A cement kiln has a requirement to operate 300 days per year, producing at a rate of 1200 tones per 24 hour day. Over the year its performance has been as follows. • Scheduled operation time 300 days, • Number of Breakdowns are 6, • Delays for Breakdowns accounted for 180 hours • Preventive Maintenance time is 80 hours Duffuaa
Problem • Shutdown due to lack of feed lasted for 120 hours • Process Slowdowns is for 60 hours at 80% rate • Wet Feed Slowdowns is 40 hours at 60% rate • Total rejected production is 2000 tones • Second quality production is 3000 tones at 50% value • Compute: Utilization, Availability, Process rate, quality rate, OEE, productive capacity Duffuaa
Measures Within The System • Work Distribution : Time Spent in each work category • Delays : Time spent waiting for instructions • parts, travel,breaks, Start and Quits • Compliance : Measures to Track Compliance with various plans, such as PM, Shutdown schedules etc. Duffuaa
Measures Within The System • Backlog : Amount of Work Planned but not Completed by Plant, Area, Craft, etc • Failure Analysis: Tracks improvement analysis, such Number of New PM Routines, Number of Root Cause Analysis of Breakdowns Undertaken. Duffuaa
Maintenance Indices For Administration • Subcontracted Hours Per Month Calculated as % of Total Subcontracted Hours Worked from Total Hours Worked • Overtime Hours Per month Calculated as %from Total Hours Worked • Work Activity Calculated by the ratio of Standard Hours Earned To Total Clock Time Duffuaa
Maintenance Indices For Administration • Current Backlog Given As : • Work Scheduled Ready To Release/One Crew week in Man-hour • Work Productivity Per Month Calculated As: Standard Hours/ Total Hours Worked * 100 • Percentage Work Orders Planned and schedules monthly from of Total Hours Worked • Percentage Scheduled Hours Versus Hours worked Duffuaa
Maintenance effectiveness • Availability • Quality • Number of failures in The system • Equipment Down Time • Emergency Man-Hours As A percentage From Total Hours • Percentage of Unscheduled Maintenance From Total Duffuaa
Maintenance effectiveness • Evaluation of Predictive Maintenance • Which Ones Can You adopt In SCECO. Duffuaa
Cost Measures • Cost Per Unit: Total Maintenance cost Per Kilo-Watt Hour • Supervision Cost As A Percentage Of Total Cost Of Maintenance • Cost of Maintenance Hour in SR. • Total Cost of Maintenance/Total Man-hours Duffuaa
Cost Measures • PM Cost As A Percentage Of Breakdown Cost • Inventory Turn rate (Rate) : Annual Consumption Cost/ Average Investment Inv • Cost Of Spare part and material to Maintenance Cost Duffuaa
Performance analysis • Make These Measures Part Of Monthly Report • Examine trend • Benchmark With Other Companies. Duffuaa
Benchmarking • Benchmarking is A continuous Improvement Methodology. It Examines The Process and Metrics to Achieve These Metrics. It Is Defined As: • The Search Of Industry Best Practices that Lead to Superior Performance Duffuaa
Types Of Benchmarking • It Is Divided In Three types : • Internal : This Deals With Comparison among Similar Operations Within Same Organization • Competitive : Comparison with The Best Of The Direct Competitors Duffuaa
Types Of Benchmarking • Functional : Comparisons With Similar Processes In Same Functions Outside One’s Industry • Generic : Comparison of Work Processes To Others Who Have Innovative Exemplar Work Processes Duffuaa
The benchmarking Process-- 10 steps • Identify What To Benchmark • Identify Whom To benchmark • Plan And Conduct The investigation • Determine The Current Performance Gap • Project Future Performance Levels Duffuaa
The benchmarking Process-- 10 steps • Communicate Benchmarking Findings and Gain Acceptance • Revise Performance Goals • Develop Action Plans • Implement Specific Actions And Monitor Progress • Recalibrate The Benchmarks Duffuaa
What To Benchmark In Maintenance • .long range planning and improvement initiatives • .organization and manpower planning • .work planning, scheduling and control • .purchasing, stores, and inventory control • .preventive and predictive maintenance Duffuaa
What To Benchmark In Maintenance • .performance measures and statistics • .information management and systems • .reliability engineering • .maintenance/production interface and communication • .management and administrative processes Duffuaa
Activity based Costing (ABC) • This Is An Approach That Is Process Based For Determining Accurate Cost For Processes. It Examines The Process By Activities Are Delivered Duffuaa
Steps Of Activity Based Costing (ABC) • Determine the key activities. • Determine the activity cost (labor, materials, services, overheads, etc.) and performance (cost/unit, time quality, etc.) Duffuaa
ABC Steps Continued • Determine the cost driver or output of the activity. • Trace this activity cost to the cost objectives;. • Evaluate the cost-effectiveness and efficiency by matching the activity cost to the process objectives Duffuaa
