KPI for breakdown analysis

Immediate corrective maintenance ratio

How much immediate corrective maintenance is done in relation to all other maintenance activities?

Immediate corrective maintenance describes the relation of planed vs. unplanned activities.
Example: Im during the last quarter, the maintenance department had to spend 45% of their time on breakdowns that required immediate action.

Needed Data

Time or number of immediate corrective jobs

Overall time or number of non-immediate maintenance jobs

Calculation:

Relevant for:

Tracked for:

Companies
Objects
Departments

Calculation based on:

Time
# Jobs
In MaintMaster:
Part of the default setup

MTBF – (MOTBF)

Mean (Operating) Time Between Failures

MTBF describes how long in average an equipment will run between breakdowns.

Needed Data:

Site-Object

Number of failures

Total (operating) time

Calculation:

Relevant for:

Tracked for:

Site-Objects

Calculation based on:

Time differences
In MaintMaster:
Part of the default setup

Top 5 Site-Objects

Top 5 site-objects with the most jobs / highest costs / most reported time…

Top 5 site-objects can be used to identify the costliest objects, objects with the most breakdowns or the most time-consuming objects.
Example: sometimes, site-objects that have the most jobs, are not the ones that cause the most trouble. Therefor, other parameters need to be looked at as well.

Needed Data:

Site-object

Job Category / Completion code

Reported time / Costs

Calculation

Relevant for:

Tracked for:

Site-Objects
Departments

Calculation based on:

Reported time
# Jobs
Costs
Completion codes
In MaintMaster:
Part of default setup

 

𝗧𝗼𝗽 𝟱 𝗢𝗯𝗷𝗲𝗰𝘁𝘀 with the most unplanned stops is one of the most important KPI to look at.

If we don’t measure which objects have the most breakdowns, there will be a lot of talk in production on what to improve but all of these initiatives will not be based on facts.

We can be even more precise in our measurement by starting to count the time that machine is in a downstate. Tracking the amount of unplanned stops in combination with breakdown hours will give you a clear picture on what to improve.

This KPI is highly dependent on operators and production personal reporting unplanned stops in a proper manner. Therefore we recommend to report back to them what improvements have been made based on their data.

This way, they will understand that each time they fill in a fault report, they actually create valuable information for the maintenance department to improve the reliability of their equipment.

Breakdown hours

Objects with the most downtime caused by breakdowns.

Breakdown hours per objects lists the objects with the most reported breakdowns

Work with follow up jobs in improvement maintenance to find the root cause and improve the availability of objects.

Needed data

Site object

Downtime caused by breakdown

Calculation

Relevant for:

Tracked for: 

Site objects
Departments

Calculation based on:

Breakdown hours
In MaintMaster:
Configured by user

One of the most effective ways to measure the reliability of your equipment is to measure its downtime. This is so important that there are often systems in place that measure downtime outside the maintenance software. If you have both an automated system in place to monitor machine downtime as well as maintenance reported downtime, you may find that the values in both systems vary a lot. That is because:

-> It may take a while for production to report an error
-> It may need some time after the repair is done for the machine to start up again

If your monitoring system is not able to differentiate between breakdown hours and other causes for the machine to stand still, you may get additional differences because of:

-> Missing materials
-> Insufficient staffing of operators
-> Break time for operators

Therefore, having both systems in place may provide useful information both for the maintenance department as well as production: By looking at differences in maintenance reported downtime and machine monitoring, we can get clues on how the operators can improve their processes as well as us, the maintenance team.

 

 

 

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