Principle Of Maintenance

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Principle Of Maintenance

&

CMMS

Performance Measurement

In

Maintenance Measurement


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Objectives

Explain the use of performance measurement

Explain the categories of maintenance for measurement

Calculate the different types of performance

measurement

Explain the steps to implement a measurement system.


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Content

2.0 Introduction

2.1 Uses of Performance Measurement

2.2 Categories of Maintenance for Measurement

2.3 Types of Measurements for Categories of Maintenance for Measurement

2.3.1 Overall Maintenance Results

2.3.2 Maintenance Productivity

2.3.3 Maintenance Organization

2.3.4 Efficiency of Maintenance Works

2.3.5 Maintenance Costs

2.3.6 Maintenance Quality

2.4 Collecting Data for Performance Measurement

2.5 Steps to Implement a Measurement system


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Introduction

Performance measurement is important for

improvement of maintenance management.

Performance measurement are only as goodas the actions they prompt.

Performance measurement will improve from

one year to the next

It will be use as stimulation in way of finding

the progression.


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Uses of Performance Measurement

Post implementation review of equipment toassess the result ofbuying and implementingnew equipment against the planned results.

Machine reliability analysis/failure rates. Labor effectiveness review measuring staff

allocation tojobs or categories ofjobs comparedto last year.

Analyses of material usage, equipmentavailability, utilization, productivity, losses, costsetc.


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Categories of Maintenance for

Measurement

Maintenance productivity -measures the effectiveness of resource

use

Maintenance organization -measures the effectiveness of the

organization and planning activities.

Efficiency of maintenance work -how well maintenance keeps up with

workload

Maintenance costs -overall maintenance cost vs. production

cost

Maintenance quality - how well the work is performed

Overall maintenance results - measures overall results


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Types of Measurements for Categories

of Maintenance for Measurement

Overall Maintenance Results

Maintenance Productivity

Maintenance Organization

Efficiency of Maintenance Works

Maintenance Costs

Maintenance Quality


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Overall Maintenance Results

Availability

Mean Time to Failure (MTTF)

Failure frequency or breakdown frequency

Mean Time to Repair (MTTR)

Production Rate Index


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Maintenance Productivity

Manpower utilization

Manpower efficiency

Materials usage

Planning and scheduling index

Breakdown time

Cost of lost production due to breakdowns


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Maintenance Organization

Planning and scheduling

Breakdown time

Cost of lost production due to breakdowns


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Efficiency of Maintenance Works

Work Order turnover


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Maintenance Costs

Overall maintenance costs per unit output

Maintenance cost versus the cost of the asset

base

Overall maintenance effectiveness index


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Maintenance Quality

Repeat jobs and repeat breakdowns


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Collecting Data For Performance

Measurement

Data is collected from Computer Maintenance

Management Systems (CMMS)

Refer Table


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Item Value

Total time full-time operation 24 x 365 = 8760 hours year

Emergency Work Orders

Last year

This year

High-priority response time

Standard

Last month

Maintenance cost ofbreakdownsStores value

Last year

Current

Stock-outs

This year

Last yearTotal production costs

Lost production time cost/hour

152

130

4 hours

3.3 hours

$135/hour

$1.8 M

$2.0 M

16

20$45 M

$5140

$40 M

Table


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Item Value

Total time full-time operation 24 x 365 = 8760 hours year

Production losses

Last month

Previous month

Asset value (replacement cost)

20 hours

25 hours

$40 M

Table


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STEPS TO IMPLEMENT A

MEASUREMENT SYSTEM

Review and select the indices that meet the

objectives of the maintenance department

and overall business. Select indices which can

be measured and keep to a minimum the

amount of extra work needed to build the

performance measures.

For each of the chosen measurements, setstandards, values and targets.


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Document the measures and targets, plus the

interpretation of each number or trend.Absolute numbers may not mean anything; so

whenever a trend is used, explain whether is

the level good or bad.

When setting up the measuring process, make

sure that the person responsible understands

the nature of the measurement, where the

data comes from and what type of analysis isrequired.


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Install the measuring procedure in the CMMS.

Publish the results so that all employees can

see both the targets and the achievements. Review and discuss measurement results for

continuous improvement


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Credits

Created by

The Mechatronics Engineering

Group 1Hosted by

Mohamad Fairulnizam

SulaimanMohd Amirul


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Principle Of Maintenance

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