MTTR /MTBF Calculation

MTTR Concept and Calculation

MTBR, MTBF and MTTR are tools to measure effectiveness of Maintenance task performed.

As we all aware that equipment downtime has direct impact on bottom line of any company
so it becomes very important to track and analyse MTBR,MTBF and MTTR.

It is used to find out reasons behind the short and long time break down duration.

Recording of breakdown

Organization uses different ways to record breakdowns in SAP Plant Maintenance module,
i.e. By separate Order type for breakdown, by breakdown tick on input screen of
notification.

It is measure duration between malfunction start and malfunction end date and time, if we
add tick breakdown check box in Notification then system default takes system date and
time as malfunction Start time and Date while Malfunction end records at the time of order
closure.

MTTR can be calculated from history details of breakdowns.

MTTR Calculation

First Breakdown 40 hrs

Second Breakdown 30

No of Breakdowns 02

so final calculation of MTTR will be

MTTR= ((40+30)/2))

MTTR = 35 Hrs.

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 MTTR /MTBF Calculation

MTBR/MTBF: - Mean Time between Repair

MTBR represents average duration between breakdowns.

MTBR is very important factor to know status of equipment health.

Here we have taken example of Gear motor for calculation purpose.

MTBF model assumes the failed system is immediately repaired.

In SAP there are few reports available for monitoring MTTR, MTBF and MTBR.

Two cases have been depicted here.

Case1: -

No. Of Failures = 6 (Denominator for MTTR, MTBR Calculations)

Total Uptime = U1 + U2 +U3 + U4 + U5 + U6 + U7. = 900 Hrs.

Total Downtime = D1 + D2 + D3 + D4 + D5 + D6. = 108 Hrs.

We know that MTTR (Mean Time to Repair in Hrs) = ( D1 + D2 + D3 + D4 + D5 + D6 ) / 6 = 18 .

Similarly MTBR (Mean Time Between Repairs in Hrs) = ( U1 + U2 +U3 + U4 + U5 + U6 + U7 ) / 6 = 150

Now,

Equipment Availability (%) is: uptime / Total Time = (900 / 1008) * 100 = 89.2

Another formula for Equipment Availability in practice is [MTBR / (MTTR + MTBR)] * 100 = (150 /
168 )*100 = 89.2

Case2: -

No. Of Failures = 2 (Denominator for MTTR, MTBR Calculations)

Suppose here too we get the same total values like:

Total Uptime = U1 + U2 +U3 = 900 Hrs

Total Downtime = D1 + D2 = 108 Hrs

MTTR (H) = ( D1 + D2) / 2 = 54 .

MTBR (H) = ( U1 + U2 + U3) / 2 = 450 .

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 MTTR /MTBF Calculation

Equipment Availability (%) is: Uptime / Total Time = (900 / 1008) * 100 = 89.2

Failure Rate :- No. Of Failure / Total Time

Duration Downtime Availability MTBR Failure

Case Failures
(H) (H) (%) (H) Rate ()
1 1008 6 108 89.2 150 0.00595
2 1008 2 108 89.2 450 0.00198

MCJB- This report is used for MTTR and MTBR calculation.

Logic of MCJB report is purely based on Breakdown, if Breakdown check box marked as
ticked then only system will consider notifications as breakdown notification else it will
consider as normal notification.

If breakdown notification gets converted into breakdown maintenance order for Material
issue or operation confirmation purpose then additional care should be taken at the time of
maintenance order closure.

At the time of maintenance order completion maintenance notification should also

complete in background.

We can also get trends of breakdown details in above reports by doing drill down.

TCODE MCJB

This helps to make report according to Equipment.

ENTER Equipment Number. Then Execute.

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 MTTR /MTBF Calculation

Use T Code - MCI7

PUT MONTH & YEAR THEN EXECUTE.

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 MTTR /MTBF Calculation