flex training contains maintenance kpis.pptx

maintenance strategies

1. Maintenance KPIs +New log

2. KPIS

3. 1. Mean Time Between Failures (MTBF) MTBF measures the average time equipment operates before a failure occurs. It provides insights into equipment reliability, which helps predict future failures. A high MTBF indicates fewer frequent failures, which improves uptime and productivity. Calculation:  MTBF=Total Operating Time / Number of Failures​ Example:  If your equipment operated for a total of 500 hours and experienced 5 failures: MTBF=(500/5​)=100 hours

4. 2. Mean Time to Repair (MTTR) MTTR calculates the average time required to repair equipment and return it to operational status. It helps understand the efficiency of maintenance processes. Lower MTTR means faster repairs and reduced downtime. Calculation:  MTTR=Total Repair Time / Number of Repairs​ Example:  If repair time totaled 50 hours for 10 repairs: MTTR=(50/10​)=5 hours

5. 3. Planned Maintenance Percentage (PMP) PMP measures the proportion of planned maintenance hours versus total maintenance hours. It indicates the effectiveness of preventive maintenance scheduling. A high PMP suggests a proactive approach, reducing unplanned downtime. Calculation:  PMP=(Planned Maintenance Hours/Total Maintenance Hours​) × 100 Example:  If planning 120 hours out of 200 maintenance hours: PMP=(120/200​) × 100=60%

6. 4. Overall Equipment Effectiveness (OEE) OEE evaluates equipment utilization by combining availability, performance, and quality. It provides a clear picture of equipment efficiency. High OEE means the equipment achieves optimal performance, resulting in high productivity and quality output. Calculation:   OEE=Availability × Performance × Quality Availability=Operating Time / Scheduled Production Time​ Performance=Actual Output / Maximum Possible Output​ Quality=Good Units Produced / Total Units Produced​ Example : If operating time is 450 hours out of 500, with 900 good units out of 1000 produced: Availability=(450/500​)=0.90 Performance=(900/1000​)=0.90 Quality=(850/900​)=0.944 OEE=0.90 × 0.90 × 0.944=0.764=76.4%

7. 5. Maintenance Backlog The maintenance backlog is the total amount of pending maintenance work. It helps prioritize tasks. Managing the backlog means that tasks are completed in a timely manner, which prevents potential failures. Calculation:  Backlog=Total Hours of Maintenance Tasks​ / Available Maintenance Hours Example:  If 300 hours of tasks are pending with 150 available hours: Backlog=(300 / 150 ​)=2 weeks

8. 6. Maintenance Cost per Unit of Production This measures total maintenance cost relative to the number of units produced. It assesses and helps analyze cost efficiency. Lower cost per unit indicates operations are working as desired, which contributes to cost savings in the long run. Calculation:  Cost per Unit=Total Maintenance Cost / Total Units Produced​ Example:  If maintenance costs $5000 for 1000 units: Cost per Unit=(5000​/1000)=5 dollars/unit

9. 7. Emergency Maintenance Percentage This metric calculates the proportion of maintenance hours spent on emergency repairs versus total maintenance hours. It provides complex data on the frequency of unexpected failures. Reducing this percentage means more stable operations and lower repair costs. Calculation:  EMP=(Emergency Maintenance Hours / Total Maintenance Hours​)×100 Example:  If emergency maintenance is 40 hours out of 200: Emergency Maintenance Percentage=(40/200​) × 100=20%

10. 8. Preventive Maintenance (PM) Compliance PM Compliance measures the percentage of scheduled preventive maintenance tasks completed on time. It confirms preventive tasks are performed as planned, which will prevent any breakdowns. Additionally, high compliance improves equipment reliability. Calculation:  PM Compliance=(Number of Completed PM Tasks / Number of Scheduled PM Tasks​)×100 Example:  If 45 out of 50 PM tasks are complete: PM Compliance=(45/50​) × 100=90%

11. Tools: Computerized Maintenance Management System (CMMS) CMMS software  centralizes maintenance data, schedules, and logs, making it an effective tool for tracking maintenance KPIs. CMMS software features automated work orders, preventive maintenance scheduling, and real-time reporting. For example, Accruent Maintenance Connection is a tool that helps organizations track KPIs to improve overall efficiency. Centralized Data:  Contains maintenance information in one place. Automated Processes:  Reduces manual tasks and errors. Real-Time Reporting:  Provides instant insights for better decision-making.

12. 2. Spreadsheets Spreadsheets are helpful for manual tracking and calculations, especially for smaller operations or as a supplemental tool. However, they can become less efficient for large-scale operations. Manual Tracking:  Suitable for minor scale data management. Flexibility:  Customizable for various tracking needs. Lack of Automation:   Inefficient and more error-prone for larger datasets. 3. Dashboards Dashboards offer visual tools that aggregate KPI data for quick reference and analysis to provide a clear, real-time view of key metrics. The layout helps teams stay informed and responsive to whatever is needed at any given moment. Visual Representation:  Easy-to-understand data visualization. Real-Time Updates : Keeps teams informed of current status. Quick Analysis:  Facilitates rapid decision-making with consolidated data views.

13. How to improve Planned maintenance? To improve PMP, focus on proactive maintenance task scheduling. Plan all preventive maintenance activities well in advance and allocate accurate resources for them. A CMMS like Maintenance Connection will automate and simplify these processes. When utilized correctly, it makes it easier to track and increase PMP.

14. Why is tracking Maintenance Cost per Unit of Production important? Tracking Maintenance Cost per Unit of Production helps an organization understand the cost-efficiency of maintenance operations. It identifies areas where maintenance costs can be reduced and guarantees effective resource allocation. Lowering this cost can and will significantly impact overall profitability.

15. CMMS preparation: What is Enterprise Resource Planning (ERP)? Enterprise Resource Planning (ERP)  is a comprehensive software platform used by organizations to manage and integrate core business processes and essential parts of their operations. Through a unified system, ERP software facilitates the flow of information between all business functions within the organization and manages connections to outside stakeholders.  It streamlines various processes by collecting an organization's shared transactional data from multiple sources, eliminating data duplication, and providing data integrity with a single source of truth.  By integrating financial management, human resources, supply chain operations, and other critical functions,  ERP systems enable organizations to improve both performance and productivity, make informed decisions, and increase efficiency .

16. Lifecycle: Installation and Configuration During the installation and configuration phase, the ERP software system is installed on the organization's infrastructure and tailored to meet the specific requirements of the business.  This involves configuring settings, such as user roles and access permissions, and integrating the ERP system with existing applications and databases. Data Migration Data migration is a crucial step in the implementation process. It involves transferring data from legacy systems or other sources to the new ERP system. This ensures that all relevant data is accurately migrated and available in the new system, allowing for a seamless transition.

17. Testing and Training Once the ERP system is installed, configured, and data migration is complete, thorough testing is conducted to ensure its functionality and data accuracy. Testing helps identify and resolve any issues before the system is deployed.  Training sessions are held to familiarize employees with the new ERP system and its features, ensuring they can effectively utilize it in their daily workflows. Go-Live and Evaluation The go-live phase marks the official launch of the ERP system across the organization. This involves transitioning from the old system to the new ERP system and making it available to all users.  Following the go-live, an evaluation is carried out to assess the effectiveness of the implementation process, identify areas for improvement, and gather feedback from users.

18. Step Description Set Clear Objectives Identify areas for improvement and define desired outcomes to align the ERP implementation with business goals. Create a Project Plan Develop a comprehensive plan outlining tasks, timelines, and resource allocation. Build an Effective Project Team Assemble a team with roles such as project sponsor, project manager, business analysts, technical leads, data specialists, change management experts, and end-user representatives. Involve Key Stakeholders Engage stakeholders early to gather input, address concerns, and ensure the system meets their needs. How To Plan Your ERP Implementation Project 

19. Soon Maintenance strategies. Failure analysis various methods.