Applying Maintenance Indicators can be a great differential for those who improve control over the business, as well as increase their efficiency and productivity, since it is through them that you know the efficiency of this activity, its costs, whether planning is being efficient or not, among other relevant information. There are several indicators that can be applied, but it is important that you know what they consist of, what is their importance and which method should be used to choose the most advantageous. Check out more about it with this reading and learn what are the 8 main indicators available!
What are Maintenance Indicators?
First, understand that a key performance indicator (KPI) consists of a metric that is applied on a business to monitor its performance, allowing to check if the changes are generating the results expected by the company. Maintenance indicators, or KPIs, are used to monitor strategic and maintenance sector planning, informing about the performance of a given sector, asset and process, what are its impacts on the company, among other related information.
What is the importance of maintenance indicators?
Maintenance causes great impact to finances and productive efficiency of the business, and maintenance indicators bring relevant data for managers to measure the performance of the area and know how to optimize it. By applying these metrics, administrators will be able to increase the efficiency of maintenance-related processes, standardize them, reduce their costs, increase their control, among other benefits that enhance the organization's competitiveness.
How to choose the ideal maintenance indicator with SMART method
Those responsible should verify that the metrics help in achieving the objectives and goals of the organization, otherwise the results of the indicators will only bring numbers that say nothing about the business. To make the proper choice of KPIs, managers can apply the SMART method, where each letter indicates an attribute that indicators must have:
- S — Specific: the purpose of the metric must be clear, simple and objective;
- M — Measurable: the results of the indicator must be quantifiable, enabling the achievement of objectives to be followed;
- A — Attainable: the KPI must be within the execution capacity of employees;
- A – Relevant: your application should bring relevant data to managers;
- T — Temporal (Timely): must be applied within a certain time period.
8 Main maintenance indicators
Although each organization needs to analyze its needs and characteristics to define its indicators, in the following topics we brought the most used and that are SMART.
Mean Time Between Failures (MTBF) shows Portuguese the total time of operation of machines until they are defective and need repair. This KPI makes it possible to check the degree of reliability of an asset. To calculate it, simply apply the following formula: MTBF = Machine operating time / Number of failures Imagine that an appliance operates for 10 hours daily, but has defects twice a day and must be repaired. This machine is idle for 30 minutes with each repair, that is, it operates for 9 hours a day. The MTBF will be found as follows: MTBF = 9 hours / 2 MTBF defects = 4.5 hours To reach minutes, just calculate 4.5 hours for 60: MTBF = 4.5 x 60 MTBF = 270 minutes
Mean Time To Repair (MTTR) Portuguese the team's ability to fix a machinery defect. Basically, the metric seeks to know the speed of employees can solve the technical problems in the devices. Here's how to calculate it: MTTR = Total maintenance time / Amount of repairs If a machine has had problems three times in a day and repairs took 15, 20 and 25 minutes, the indicator calculation will be: MTTR = 60 / 3 MTTR = 20 minutes
Backlog indicates the accumulation of pending activities for employees. Your result shows the time it takes for maintenance personnel to complete their activities. Before calculating this metric it is important to add Man-Time (HH) and the Work Order (OS), result ing in "HH OS". As for HH, it is necessary to perform the following calculation to reach the available HH: AVAILABLE HH = Total Man-hour (HHT) x Percentage of productivity As for Service Order, it is usually divided into four 4 phases:
- Planning: preparation of the necessary resources for each OS;
- Programming: choice of the employee who will comply with the OS;
- Execution: fulfilling order in practice;
- Control: Managers monitor order results.
After doing these two calculations, you can apply the Backlog formula: Backlog = Σ HH OS Planned + Σ HH OS Pending + Σ HH OS Scheduled + Σ HH OS Executed / HH available
Availability (A) means availability in Portuguese and indicates the time that a good is accessible to operate and how it is programmed. The higher this value, the better it will be for the organization. The calculation of this metric is done using mtbf and mttr, understand how: A = MTBF / (MTBF + MTTR) x 100 If the MTBF of an equipment is 270 and the MTTR for20, the A will be: A = 270 / (270 + 20) x 100 A = 270 / 290 x 100 A = 0.9310 x 100 A = 93.10%
Estimated Replace Value (ERV) is a financial indicator that demonstrates the maintenance cost that is employed on each equipment. It can be used to conclude whether it is better to keep the equipment or purchase a new one. See its formula: CPMV = (Total maintenance cost / Purchase value of a new asset) x 100 The account will result in the CPMV rate which, if above 6% in a year, it will be more advantageous to exchange the equipment. Imagine that the company spent R$ 9,000 on the maintenance of a machine during the year, and the acquisition of a new one is R$ 150,000. See account: CPMV = (9,000.00 / R$ 150,000.00) x 100 CPMV = 0.06 x 100 CPMV = 6%
The Cost of Maintenance on Billing (CMF) proves the efficiency of maintenance management, that is, how much should be spent on maintenance to avoid waste. In this account it is important to include labor, depreciation, materials and insums, outsourcing services, among others. CMF = (Total maintenance cost / Gross billing) x 100 If the company spends R$ 1 million on maintenance and revenues are R$ 750 million, the CMF will be: CMF = (750,000.00 / 25,000,000.00) x 100 CMF = 0.03 x 100 CMF = 3% According to abraman's 2017 National Document, the average maintenance cost in relation to billing is around 4%.
MP indicates how much of the preventive maintenance plan is being fulfilled. To calculate it, you must divide preventive maintenance tasks by scheduled actions. Understand: MP = Preventive maintenance activities / Scheduled preventive maintenance plan x 100
Similar to the previous one, it verifies the predictive maintenance plan is being fulfilled. It relates the tasks of the predictive maintenance plan to the preventive one. Check out its formula: MPd = Tasks performed in the predictive maintenance plan / Scheduled actions of the maintenance plan
Learn more about maintenance indicators with SANMobile
In practice, the application and monitoring of maintenance indicators are automated by a specialized technology, such as SANMobile. This application brings several features that increase productivity, minimize the occurrence of errors, reduce costs and time spent on transactional processes, among other benefits. It allows teams to access and update Maintenance Orders, site and equipment data, brings a dashboard for allocation management, dispatches and execution of maintenance orders, has a panel for individual control of orders and more. Maintenance indicators are powerful tools capable of generating impactful positive changes in your business. But it is necessary that the monitoring of metrics is constant and efficient, which can be done with SANMobile. Want to know more about our technology, its benefits and services? Contact us and solve your questions!