World Class Operatian and Maintenance

Sumber:
http://www.wcm-society.com/images/pdf/p02.pdf

Benchmarking
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Benchmarking is the process of comparing one's business processes and

performance metrics to industry bests and/or best practices from other
industries.
Dimensions typically measured are quality, time, and cost

WHAT IS WORLD-CLASS MAINTENANCE?

1. The best simply do the basics very well.*
2. The best also take a proactive approach to the management of maintenance.*
* Engineers Digest February 2001

World-Class Maintenance Best Practices

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Planned Maintenance Work > 90%

Breakdown/Crisis Work < 3%
Maintenance Schedule Compliance > 90%
Craftsmen per Planner = 15 to 20
Maintenance Overtime < 5%
Maintenance Direct Work > 65%
MRO Inventory Turns > 3 per year
Accurate CMMS Data
Annual Maintenance Cost < 2.5% of ERC (Estimated Replacement Cost )

Characteristics of World-Class Maintenance Performance

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Clear Vision and Mission for Maintenance

Proactive not Reactive
Managed Costs
Total Facility Understanding of & Participation in Maintenance
Top Management Support

Sumber:

http://www.danielpenn.com/how-do-you-define-world-class-maintenance/
Youd probably agree that striving for World Class Maintenance status (WCM) is a
good thing. It may even be in your mission statement. We all want to be the best of
the best, thats a given, but what exactly does it mean and how do we know when
we get there?
An athlete knows there are world records to beat because records in any given
event are measured in seconds or pounds or feet. These metrics signal if the athlete
has beat previous records, elevating her or him to world class. In business,
organizations such as Fitch, Moodys, and Standard & Poors rate companies from
AAA (world class) through D. Again, these services use generally accepted
measures that let companies know when they achieve world class status.
Given all the engineering and metrics involved, one would expect a similarly crisp,
uniform, yes/no definition of WCM, right?
Try this: do a Google search for world class maintenance. I did, and got about
586,000,000 results (in .24 seconds, no less). Scan through some of the results. Do
you see any common references cited or any uniform definition of WCM? Me neither.
To be fair, there are many consulting and engineering firms, ours included, that
provide services for improving maintenance effectiveness and efficiency to their
own definition of world class and virtually all have a set of benchmarks they use to
assess maintenance performance.
Here are some common examples of world class performance from a muchlarger
unofficial list that seems to have been developed by consensus over the years:

Maintenance Schedule Compliance > 90%

Maintenance Overtime < 5%
Maintenance Direct Work >75%
Planned Maintenance Work > 90%
PM schedule compliance is 100%.
Percent of work covered by a work order =100%
Work order actual hours / work order hours planned = 90 110%
Equipment Availability =90%+
Equipment Productivity =95%+
Overall equipment effectiveness =77%+
And so on

Some say WCM means being in the top 5% of certain metrics. Certainly it would be
great to be way up there but should that be the only measure of WCM? Or is this

more akin to being the one-eyed man in the kingdom of the blind youre up here
only because everyone else is down there?
In other words, is WCM just the result of achieving benchmarks that others dont?
What if the grading is not on the curve, as it were? My old math teacher used to say
he didnt care how well we did against each other but against the right answers. No
one was guaranteed an A for answering more questions correctly than the rest of
the class.
From the 4th page of search results I found this gem that goes more to the point:
But there are no world-class maintenance organizations. Rather, there are worldclass industrial organizations that include a world-class maintenance organization.
Maintenance, by itself, is a service provider dependent on the support and
cooperation of other departments. When that service is exceptional, it is made that
way because maintenance is operating in an environment that requires that it be
exceptional. Managers have created an environment in which maintenance can be
exceptional. World-class Maintenance: An Ambitious Worthwhile Goal, By Paul
D. Tomlingson, published in Coal Age, 14 April 2014
The quote was about the mining industry but it could have been said about any
maintenance organization. I think this illustrates one of two key points I want to
make about WCM:
1.

WCM is not just about the maintenance practices of the maintenance

organization in a vacuum. It is about the way the entire organization uses all
the means at its disposal to protect its ability to produce exceptional value for
its customers.
2.
WCM is a journey, not a destination; a process, not a product.
There is no shortage of metrics, benchmarks, and strategies to help keep you on the
WCM path of continuous improvement. But as the quote above suggests,
exceptional performance comes from being part of an organization that requiresit.
This means were talking about having a WCM mindset that requires nothing less
than excellence in all facets of maintenance and the production of value for the
customer.
Does your company do all it can to consistently enable excellence within your
maintenance organization? Do you have a WCM mindset?
Now we want to hear from you. Tell us about your WCM journey and the lessons
youve learned along the way. What do you do to maintain a culture that supports
WCM?