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1. To gain further information on the special nature of lagging and leading indicators of performanceand their critical differences , view the Shire
slideshow 'Lean Maintenance'
Notes
2. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'
Engineering Business
Manager Role Manager Role Indicator Comment
Indicator (Any BSI
Perspective Perspective Indicator's Typical Ratio Numerator Ratio Denominator Typical
Typical
designations
Name Reporting
Target Value refer to BSI
Strate Period 15341)
Lead or Lead or
Tactical Goal gic
Lag Lag
Goal
Total Maintenance Cost X Assets Replacement Value 2 to 4, Year BSI E1
IND
Lag Cost Lag Cost Fixed asset ratio 100% trend
1 down
Total Maintenance Cost Quantity of output Trend down Year/ BSI E3
Maintenace cost per Quarter
2 Lag Cost Lead Cost
unit produced
Total contractor cost X 100% Total Maintenance Cost Optimise Month/ BSI E10
Availability Quarter
4 Lead
versus Cost
Lead Cost Contractor cost ratio
Total cost of maintenance Average inventory value of Trend up Year/ BSI E12
Availability materials maintenance materials Quarter
5 Lead
versus Cost
Lead Cost Stores turnover
Maintenance shutdown cost X Total Maintenance Cost Trend down Year BSI E20
Delive
Availability, 100%
6 Lead
Cost
Lead ry, Shutdown ratio
Cost
Qualit
y, Achieved up time during required Required time Trend up, Month BSI T2
Delive time X 100% target >
7 Lag Availability Lead
ry,
Availability
95%
Cycle,
Cost
Total Operating time Number of maintenance work- Trend up Month
Mean time between orders causing downtime
8 Lag Availability NA NA
downtime work-orders
Qualit
y, Total Operating time Number of failures causing Trend up Month BSI T17
Availability,
Delive MTBF downtime
9 Lag Cost, Lead
ry, (Mean Time Between
Compliance Failure)
Cycle,
Qualit
Cost
y, Total number of plant stoppages Loading time Trend down Month
Availability,
Delive due to failure
10 Lag Cost, Lead
ry,
Failure frequency
Compliance
Cycle,
Delive
Cost Total stoppage time due to failure Loading time 0.15. Trend Month
Availability, ry,
X 100% down
11 Lag Cost, Lead Cycle Failure severity rate
Compliance Time,
Cost
Availability, Number of systems covered by a Total number of systems 10 to 15 Month/ BSI T18
Cost, critical analysis X 100% Quarter
12 Lead
Compliance,
NA NA Risk Analysis ratio
Capability
Man-hours used for planning in a Total internal maintenance 5 to 10 Month BSI T19
Availability,
systematic maintenance planning personnel man-hours
13 Lead Cost, NA NA Planning ratio
process X 100%
Compliance
Number of assets in the condition Total number of candidate items 20 Month/ See: Condition-
Availability, monitoring program X100% for condition monitoring Trend up Quarter based
Condition monitoring maintenance
14 Lead Cost, NA NA
coverage ratio ratio BSI O19
Compliance
Delive
Total time to restoration Number of failures Trend down Month BSI T21
ry,
15 Lag
Availability,
Lead Cycle MTTR
Compliance
Time, (Mean Time To Repair)
Qualit
Cost
y, Production operator maintenance Total direct maintenance personnel Trend up Month BSI O4
Availability,
Delive Auto-maintenance ratio man-hours X 100% man-hours
16 Lead Cost, Lead
ry, (Autonomous
Compliance Maintenance)
Cycle,
Cost Planned and scheduled Total maintenance man-hours Trend up Month BSI O5
Planned & Scheduled maintenance man-hours X 100% available
17 Lead Cost NA NA
Work ratio
Immediate Corrective maintenance Total maintenance man-hours Trend down, Month BSI O17
Availability,
Emergency maintenace man-hours X 100% < 10
22 Lead Cost, NA NA
man-hour ratio
Compliance
Number of Immediate Corrective Total number or maintenace work- Trend down, Month
Availability,
Emergency maintenace maintenance work- orders completed < 10
23 Lead Cost, NA NA
work order ratio orderscompleted X 100%
Compliance
Number of major assets/systems Total number of major Target 100% Quarter
Availability,
with PM routines assets/systems
24 Lead Cost, NA NA PM Routine Incidence
Compliance
Preventive maintenance man- Total maintenance man-hours Trend up Month BSI O18
Availability,
Preventive maintenace hours X 100%
25 Lead Cost, NA NA
ratio
Compliance
Number of PM jobs completed X Number of PM jobs scheduled Target 100 Month
Availability,
100%
26 Lead Cost, NA NA PM performance
Compliance
Condition based maintenance Total maintenance man-hours Trend up Month BSI O19
Availability,
Condition-based man-hours X 100%
27 Lead Cost, NA NA
maintenance ratio
Compliance
Number of work orders performed Total number of scheduled work Trend up, Month BSI O22
Availability,
as scheduled X 100% orders target 100%
28 Lead Cost, NA NA Schedule compliance
Compliance
Number of maintenance internal Total internal maintenance man- 3 to 5 Nmonth/ BSI O23
Availability,
personnel man-hours for training X hours Quarter
29 Lead Cost, NA NA Training ratio
100%
Compliance
Number of internal direct Number of internal direct Target 100% Quarter/ BSI O24
Availability,
maintenance people using maintenance personnel Year
30 Lead Cost, NA NA CMMS usage ratio
software X 100%
Compliance
Number of approved work orders Total number of incomplete work Stable Month
Availability, over 3 months old orders
31 Lead
Compliance
NA NA Backlog age
Total estimated manhours for all Actual available hours to schedule To target. Say, Month
Availability, Work backlog outstanding work orders each week about 4 man
32 Lead
Compliance
NA NA
(man weeks) weeks
Total cost of maintenance materials X Total cost of direct labour To target Month
Cost 100%
35 Lag
(Productivity)
NA NA Materials/Labour ratio
Total internal direct man-hours Total internal direct man-hours Trend up Month
Cost worked X 100% available
36 Lead
(Productivity)
NA NA Manpower utilisation
Quality
, Cumulative response time of all Total number of Emergency priority Trend down or Month
Response time -
Availability, Deliver Emergency priority service calls service calls stable
37 Lead
Compliance
Lag
y,
Emergency service
calls
Cycle,
Quality
Cost
, Cumulative response time to all Total number of Urgent priority service Trend down or Month
Availability, Deliver Response time - Ugent priority service calls calls stable
38 Lead
Compliance
Lag
y, Urgent service calls
Cycle,
Quality
Cost
, Number of service calls within the Total number of service calls Trend up or Month
Availability, Deliver target response time stable
39 Lead
Compliance
Lag
y,
Service level
Cycle,
Cost Cumulative Fix/Make-Safe repair Total number of Emergency priority Trend down or Month
Fix/Make-Safe time -
Availability, time of all Emergency priority service service calls stable
40 Lead
Compliance
NA NA Emergency priority
calls
service calls
Number of rework jobs X 100% Total number of jobs Trend down Month
Availability,
41 Lead Cost, NA NA Rework rate
Compliance
Quality AS DEFINED AS DEFINED Trend up Month
Availability,
,
42 Lag Cost, Lead/Lag
Deliver
Satisfaction Index
Compliance
y
Total number of work orders None Trend down or Month
Availability, registered stable
43 Lead
Compliance
NA NA Work-order volume
Notes: 1. These indicators have been selected from the list on the Maintenance Indicator tab of this Workbook
2. To gain further information on the special nature of lagging and leading indicators of performance, view the Shire slideshow
'Lean Maintenance'
3. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'
100%
Trades/Employee Group Mechanical (Note: sum of all internal tradespersons can be assumed to be the direct internal personnel)
Electrical
Instrumentation
Multiskilled
Production operator
Use of CMMS Number of direct internal maintenance people using the CMMS for more than 5% of their working time
Complement Total maintenance personnel (direct + indirect) List all maintenance staff in system, divided between direct and indirect
Total number of employees (in the enterprise)
Other Maintenance KPIs & Metrics 2009 Shire Systems Ltd
Typical Typical
Indicator's Typical Applicable
Area/Group Level ID Numerator Denominator Sectors
Target Reporting Comment
Name Value Period
Total cost of maintenance X100% Net sales turnover Year
Turmover ratio
Hours the equipment was available to run Total hours in the reporting time period 96
Plant availability at capacity X 100%
Total overtime manhours worked by Total regular manhours of indirect <2 Month
Overtime rate - indirect indirect maintenance personnel during maintenance personnel during period
internal personnel period X 100%
Number of assets in the condition Total number of candidate items for 20 Quarter/ Year
Condition monitoring monitoring program X100% condition monitoring
coverage
Number of faults found X100% Number of devices surveyed <3 Quarter/ Month
Thermography survey
Number of defective steam traps found X Number of steam traps surveyed < 10 Quarter/ Month
Steam trap survey 100%
Number of approved work orders over 3 Month
Age of backlog work-
months old
orders
Number of PM jobs completed X 100% Number of PM jobs scheduled Month
PM performance
Total estimated manhours for all Actual available hours to schedule each ~4 man Month
Work backlog (man outstanding work orders week weeks
weeks)
Total estimated man-hours for completed Total actual man-hours for completed work Month
Man-hour estimation work orders X 100% orders
accuracy
Total actual cost of work X 100% Total estimated cost of work within 10 Quarter
Cost estimation
accuracy
Total cost of planned and estimated jobs Total cost of all jobs Quarter/ Month
Volume of estimated X 10%
work
Number of material requisitions met from Total number of material requisitions Month
Stores issue service
stock
level
Total cost of maintenance materials Total cost of maintenance Month
Material ratio
Total internal direct man-hours worked X Total internal direct man-hours available Quarter
Manpower utilisation 100%
Cumulative response time of all Priority 1 Total number of Priority 1 service calls Month
Response time - Priority service calls
1 service calls
Cumulative response time to all Priority 2 Total number of Priority 2 service calls Month
Response time - Priority service calls
2 services calls
Number of service calls within the target Total number of service calls Month
Response performance response time
Cumulative Fix/Make Safe repair time of Total number of Priority 1 service calls Month
Fix/Make Safe time - all Priority 1 service calls
Priority 1
AS DEFINED AS DEFINED
Satisfaction Index