Maintenance KPIs April 28.pptx

Maintenance KPIs

1. April 28, 2022 Key Performance Indicators (KPIs) Related to SAP-PM Module You cannot control what you cannot measure. - Peter Drucker Maintenance Dept.(Goth Machhi)

2. Quick Facts KPI implementation demands sheer commitment from top most level as it requires involvement of all departments. At department level (in isolation), these KPIs can be implemented with certain modifications/compromises. In FFC-GM, at present SAP-PM module is being utilized only for material issuance. FFC is the only company in fertilizer sector which yet has to consider maintenance KPI implementation.

3. Major Societies Governing Maintenance Reliability Practices

4. Proactive to Reactive Ratio Pending & Overdue Notifications 1 2 Selected KPIs Pending & Overdue Workorders 3

5. Mean Time Between Failure (MTBF) Maintenance Cost 1 2 Monitoring Only ( Non-KPI)

6. Proactive to Reactive Ratio Pending & Overdue Notifications 1 2 Selected KPIs Pending & Overdue Workorders 3

7. Predictive/Condition based Maintenance Preventive Maintenance PROACTIVE MAINTENANCE Corrective Maintenance Breakdown / Failure REACTIVE MAINTENANCE Your Text Here Refurbishments / Modifications Any other planned work Proactive & Reactive Maintenance

8. All Work Target 100% Capital Work Target Varies Predictive/CBM Target 15% Corrective Work from Structured Work Program Target 50% Non-Capitalized Work Target 10 – 15% Preventive Maintenance Target 15% Corrective Work from Structured Work Program Target 5% Structured Work Identification Target 30% Corrective Maintenance Work Target 55% Other Work Target < 5% Improvement & Modification Work Target 10 to 5%

9. What is KPI This metric measures the ratio of proactive to reactive work KPI-I : Proactive to Reactive Work Ratio 1 Reactive work: Signifies all activities that cannot be scheduled/planned – Includes corrective, breakdown and unplanned work. Proactive work: Consists of all maintenance work carried out on the basis of Preventive, predictive, modification or any other planned maintenance work.

10. Mechanical Seal/Gland Leakage which can be planned without jeopardizing daily schedule Corrective work as a result of thickness monitoring PROACTIVE MAINTENANCE Proactive & Reactive Maintenance Work on the basis of observation of operator/unit (insulation rectification etc.) Mechanical seal/ Gland leakages which needs to be attended immediately Pipeline or other process leakages REACTIVE MAINTENANCE Any work which creeps in to maintenance schedule

11. Project analysis slide 8 Proactive to Reactive work ratio SAP Notification & Work Orders Types

12. What is KPI This metric measures the ratio of proactive to reactive work Proactive to Reactive Work Ratio 1 2 The KPI can help identify bad actors and improve inspection / maintenance plans. World Class Value Our Value (Mach-II year 2021) 6 : 1 3.25 : 1 Reactive (unplanned) work: signifies all activities that cannot be scheduled/planned – Includes all unplanned and breakdown work orders. Proactive work: consists of all maintenance carried out on the basis of Preventive, predictive, modification or any other planned maintenance work. Our Value (EM-II Urea: one Quarter) 4.1 : 1

13. Project analysis slide 8 Proactive to Reactive work ratio KPI-II: Notification Status This metric measures the status (in percentage) of notifications at various stages notifications 1 Stages Overdue Outstanding In-process Completed Postponed Targets are set on the basis on notification priority. No standard benchmarking available. Target will be fixed after analyzing our own data. Target may be different for each area.

14. What is KPI Frequently, important/urgent jobs are being executed without notifications. Notifications: Present Issues 1 2 3 4 Mostly notifications are being raised for routine high notification type regardless of job priority. Most of the notification raised are of low priority jobs. Poor description/insufficient data in notification.

15. Project analysis slide 8 Proactive to Reactive work ratio SAP Notification Screen Shot

16. Project analysis slide 8 Proactive to Reactive work ratio KPI-III: Work Orders Status This metric measures the status (in percentage) of work orders at various stages notifications 1 Stages Created Released Overdue Completed As per standard, should be calculated on Man-hours basis No standard benchmarking available. Target will be fixed after analyzing our own data. Target may be different for each area. Targets are set on the basis on equipment criticality.

17. Project analysis slide 8 Proactive to Reactive work ratio

18. What is KPI Sometimes work orders are not created and notifications are closed after completion of job, without creating work orders. Work Order: Present Issues 1 2 3 4 Sometimes work orders are created without notifications where material issuance is required. Issuance of material in improper work orders. Review of damage and cause codes.

19. Project analysis slide 8 Proactive to Reactive work ratio SAP Work Order Screen Shot

20. Mean time between failure (MTBF) Maintenance Cost 1 2 Monitoring Only ( Non-KPI)

21. Project analysis slide 8 Proactive to Reactive work ratio Mean Time Between Failures This metric measures the average length of operating time between failures for an asset or component The objective is to assess the reliability of a repairable asset or component, perform gap analysis and target reliability improvement of low MTBF assets. 1 2 ORIGINAL: MTBF = Total Operating Time / Number of Failures MODIFIED: MTBF = Total Time Elapsed / Number of Failures

22. Project analysis slide 8 Proactive to Reactive work ratio Mean Time Between Failures Data needs to be entered for monitoring Proper equipment tag/functional location Damage code & cause code (need to be revised) Actual start and finish date 3 4 For automated calculations, IT will be involved

23. Project analysis slide 8 Proactive to Reactive work ratio Maintenance Cost This metric is the measure of the total maintenance cost required incurred on an equipment during certain time period. The objective is to assess the reliability of a repairable asset or component, perform gap analysis and target reliability improvement of low MTBF assets. 1 2