Maintenance Performance Indicators (Typical Measures or Metrics) 2009 Shire Systems Ltd

1. To gain further information on the special nature of lagging and leading indicators of performanceand their critical differences , view the Shire
slideshow 'Lean Maintenance'
Notes

2. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'

Engineering Business
Manager Role Manager Role Indicator Comment
Indicator (Any BSI
Perspective Perspective Indicator's Typical Ratio Numerator Ratio Denominator Typical
Typical
designations
Name Reporting
Target Value refer to BSI
Strate Period 15341)
Lead or Lead or
Tactical Goal gic
Lag Lag
Goal
Total Maintenance Cost X Assets Replacement Value 2 to 4, Year BSI E1
IND
Lag Cost Lag Cost Fixed asset ratio 100% trend
1 down
Total Maintenance Cost Quantity of output Trend down Year/ BSI E3
Maintenace cost per Quarter
2 Lag Cost Lead Cost
unit produced

Average inventory value of Asset Replacement Value Trend down Year/

maintenance materials X 100% Quarter
3 Lag Cost Lead Cost Inventory ratio

Total contractor cost X 100% Total Maintenance Cost Optimise Month/ BSI E10
Availability Quarter
4 Lead
versus Cost
Lead Cost Contractor cost ratio

Total cost of maintenance Average inventory value of Trend up Year/ BSI E12
Availability materials maintenance materials Quarter
5 Lead
versus Cost
Lead Cost Stores turnover

Maintenance shutdown cost X Total Maintenance Cost Trend down Year BSI E20
Delive
Availability, 100%
6 Lead
Cost
Lead ry, Shutdown ratio
Cost
Qualit
y, Achieved up time during required Required time Trend up, Month BSI T2
Delive time X 100% target >
7 Lag Availability Lead
ry,
Availability
95%
Cycle,
Cost
 Total Operating time Number of maintenance work- Trend up Month
Mean time between orders causing downtime
8 Lag Availability NA NA
downtime work-orders
Qualit
y, Total Operating time Number of failures causing Trend up Month BSI T17
Availability,
Delive MTBF downtime
9 Lag Cost, Lead
ry, (Mean Time Between
Compliance Failure)
Cycle,
Qualit
Cost
y, Total number of plant stoppages Loading time Trend down Month
Availability,
Delive due to failure
10 Lag Cost, Lead
ry,
Failure frequency
Compliance
Cycle,
Delive
Cost Total stoppage time due to failure Loading time 0.15. Trend Month
Availability, ry,
X 100% down
11 Lag Cost, Lead Cycle Failure severity rate
Compliance Time,
Cost
Availability, Number of systems covered by a Total number of systems 10 to 15 Month/ BSI T18
Cost, critical analysis X 100% Quarter
12 Lead
Compliance,
NA NA Risk Analysis ratio
Capability
Man-hours used for planning in a Total internal maintenance 5 to 10 Month BSI T19
Availability,
systematic maintenance planning personnel man-hours
13 Lead Cost, NA NA Planning ratio
process X 100%
Compliance
Number of assets in the condition Total number of candidate items 20 Month/ See: Condition-
Availability, monitoring program X100% for condition monitoring Trend up Quarter based
Condition monitoring maintenance
14 Lead Cost, NA NA
coverage ratio ratio BSI O19
Compliance
Delive
Total time to restoration Number of failures Trend down Month BSI T21
ry,
15 Lag
Availability,
Lead Cycle MTTR
Compliance
Time, (Mean Time To Repair)
Qualit
Cost
y, Production operator maintenance Total direct maintenance personnel Trend up Month BSI O4
Availability,
Delive Auto-maintenance ratio man-hours X 100% man-hours
16 Lead Cost, Lead
ry, (Autonomous
Compliance Maintenance)
Cycle,
Cost Planned and scheduled Total maintenance man-hours Trend up Month BSI O5
Planned & Scheduled maintenance man-hours X 100% available
17 Lead Cost NA NA
Work ratio

Man-hours for continuous Total maintenance personnel man- 5 to 10 Month BSI O8

Availability, improvement X 100% hours
Cost, Continuous
18 Lead
Compliance,
NA NA
improvement ratio
Capability
 Qualit
y, Direct maintenance personnel on Total direct maintenance personnel Minimise Quarter/ BSI O10
Delive shift X 100% Year
Cost versus ry,
19 Lead
Availability
Lead
Cycle
Shift cover ratio
Time
versus
Delive
Cost Number of internal Multi-skilled Number of internal maintenance Maximise Month/ BSI O15.
ry, First Fix
Availability, maintenance personnel X 100% personnel Quarter
20 Lead
Cost
Lead Cycle Multiskilled ratio capability,
Time, especially on
Cost shift
Corrective maintenance man- Total maintenance man-hours Trend down Month BSI O16
Availability,
Corrective maintenance hours X 100%
21 Lead Cost, NA NA
ratio
Compliance

Immediate Corrective maintenance Total maintenance man-hours Trend down, Month BSI O17
Availability,
Emergency maintenace man-hours X 100% < 10
22 Lead Cost, NA NA
man-hour ratio
Compliance
Number of Immediate Corrective Total number or maintenace work- Trend down, Month
Availability,
Emergency maintenace maintenance work- orders completed < 10
23 Lead Cost, NA NA
work order ratio orderscompleted X 100%
Compliance
Number of major assets/systems Total number of major Target 100% Quarter
Availability,
with PM routines assets/systems
24 Lead Cost, NA NA PM Routine Incidence
Compliance
Preventive maintenance man- Total maintenance man-hours Trend up Month BSI O18
Availability,
Preventive maintenace hours X 100%
25 Lead Cost, NA NA
ratio
Compliance
Number of PM jobs completed X Number of PM jobs scheduled Target 100 Month
Availability,
100%
26 Lead Cost, NA NA PM performance
Compliance
Condition based maintenance Total maintenance man-hours Trend up Month BSI O19
Availability,
Condition-based man-hours X 100%
27 Lead Cost, NA NA
maintenance ratio
Compliance
Number of work orders performed Total number of scheduled work Trend up, Month BSI O22
Availability,
as scheduled X 100% orders target 100%
28 Lead Cost, NA NA Schedule compliance
Compliance
Number of maintenance internal Total internal maintenance man- 3 to 5 Nmonth/ BSI O23
Availability,
personnel man-hours for training X hours Quarter
29 Lead Cost, NA NA Training ratio
100%
Compliance
 Number of internal direct Number of internal direct Target 100% Quarter/ BSI O24
Availability,
maintenance people using maintenance personnel Year
30 Lead Cost, NA NA CMMS usage ratio
software X 100%
Compliance
Number of approved work orders Total number of incomplete work Stable Month
Availability, over 3 months old orders
31 Lead
Compliance
NA NA Backlog age

Total estimated manhours for all Actual available hours to schedule To target. Say, Month
Availability, Work backlog outstanding work orders each week about 4 man
32 Lead
Compliance
NA NA
(man weeks) weeks

Average age of equipment Average useful life of equipment To target. Year

Availability, Stable or trend
Cost, Equipment down
33 Lag
Compliance,
NA NA
obsolescence ratio
Capability

Cost of replacing obsolete items X Total cost of maintenance 15 to 20 Quarter/

Availability, 100% Year
IND Lead
Cost,
NA NA Plant renovation rate
2 Compliance,
Capability

Total cost of maintenance materials X Total cost of direct labour To target Month
Cost 100%
35 Lag
(Productivity)
NA NA Materials/Labour ratio

Total internal direct man-hours Total internal direct man-hours Trend up Month
Cost worked X 100% available
36 Lead
(Productivity)
NA NA Manpower utilisation
Quality
, Cumulative response time of all Total number of Emergency priority Trend down or Month
Response time -
Availability, Deliver Emergency priority service calls service calls stable
37 Lead
Compliance
Lag
y,
Emergency service
calls
Cycle,
Quality
Cost
, Cumulative response time to all Total number of Urgent priority service Trend down or Month
Availability, Deliver Response time - Ugent priority service calls calls stable
38 Lead
Compliance
Lag
y, Urgent service calls
Cycle,
Quality
Cost
, Number of service calls within the Total number of service calls Trend up or Month
Availability, Deliver target response time stable
39 Lead
Compliance
Lag
y,
Service level
Cycle,
Cost Cumulative Fix/Make-Safe repair Total number of Emergency priority Trend down or Month
Fix/Make-Safe time -
Availability, time of all Emergency priority service service calls stable
40 Lead
Compliance
NA NA Emergency priority
calls
service calls
 Number of rework jobs X 100% Total number of jobs Trend down Month
Availability,
41 Lead Cost, NA NA Rework rate
Compliance
Quality AS DEFINED AS DEFINED Trend up Month
Availability,
,
42 Lag Cost, Lead/Lag
Deliver
Satisfaction Index
Compliance
y
Total number of work orders None Trend down or Month
Availability, registered stable
43 Lead
Compliance
NA NA Work-order volume

Total number of outstanding work None Stable Month

Availability, orders
44 Lead
Compliance
NA NA Work-order backlog

Total number of work orders None Stable Month

Availability, Work-order completion completed during the period
45 Lead
Compliance
NA NA
rate
Quality
, Number of unexpected equipment None Trend down Month
Availability,
Deliver failures resulting in downtime
46 Lag Cost, Lag
y,
Plant failure rate
Compliance
Cycle,
Cost Number of man-hours on continuous None To target Month
Availability, improvenment activity
Cost, Continuous
47 Lead
Compliance,
NA NA
improvement trend
Capability

Availability, Total direct man-hours worked None Trend down Month

Internal direct man-
48 Lag Cost, NA NA
hour trend
Compliance
Total cost of contractors None To target Quarter
Availability
49 Lag
versus Cost
Lag Cost Contractor cost trend

Total value of parts inventory None Trend down Quarter

Availability
50 Lag
versus Cost
Lag Cost Inventory trend

Indicators can check the same parameter from different perspectives

Leading Indicators of Maintenance Performance -
Engineering Manager's perspective 2009 Shire Systems Ltd

Notes: 1. These indicators have been selected from the list on the Maintenance Indicator tab of this Workbook
2. To gain further information on the special nature of lagging and leading indicators of performance, view the Shire slideshow
'Lean Maintenance'
3. You are strongly advised to obtain a copy of BSI 15341 : 2007 - 'Maintence. Maintenance key performance indicators'

Engineering Manager Business Manager

Role Perspective Role Perspective Indicator Comment (Any
Indicator BSI
Indicator's Typical Ratio Typical
ID Ratio Numerator Typical designations
Name Denominator Reporting refer to BSI
Lead or Target Value
Lead or Lag Tactical Goal Strategic Goal Period 15341)
Lag

Total contractor Total Maintenance Optimise Month/ Quarter BSI E10

Availability versus
4 Lead Lead Cost Contractor cost ratio cost X 100% Cost
Cost

Total cost of Average inventory Trend up Year/ Quarter BSI E12

maintenance value of
Availability versus materials maintenance
5 Lead
Cost
Lead Cost Stores turnover
materials

Maintenance Total Maintenance Trend down Year BSI E20

shutdown cost X Cost
6 Lead Availability, Cost Lead Delivery, Cost Shutdown ratio 100%

Number of Total number of 10 to 15 Month/Quarter BSI T18

systems covered systems
Availability, Cost, by a critical
12 Lead Compliance, NA NA Risk Analysis ratio analysis X 100%
Capability

Man-hours used Total internal 5 to 10 Month BSI T19

for planning in a maintenance
systematic personnel man-
Availability, Cost, maintenance hours
13 Lead
Compliance
NA NA Planning ratio
planning process
X 100%
 Number of assets Total number of 20 Month/ Quarter See:
in the condition candidate items Trend up Condition-
Condition monitoring for condition based
Availability, Cost, maintenance
14 Lead
Compliance
NA NA monitoring coverage program X100% monitoring ratio BSI O19
ratio

Production Total direct Trend up Month BSI O4

operator maintenance
maintenance personnel man-
Availability, Cost, Quality, Delivery, Operator
16 Lead
Compliance
Lead
Cycle, Cost maintenance ratio
man-hours X hours
100%

Planned and Total maintenance Trend up Month BSI O5

scheduled man-hours
Planned & maintenance available
17 Lead Cost NA NA Scheduled Work man-hours X
ratio 100%

Man-hours for Total maintenance 5 to 10 Month BSI O8

Availability, Cost, continuous personnel man-
Continuous
18 Lead Compliance, NA NA
improvement ratio improvement X hours
Capability 100%

Direct Total direct Minimise Quarter/ Year BSI O10

maintenance maintenance
Quality, Delivery, personnel on shift personnel
Cost versus
19 Lead
Availability
Lead Cycle Time Shift cover ratio X 100%
versus Cost

Number of Number of internal Maximise Month/ Quarter BSI O15.

internal Multi- maintenance First Fix
skilled personnel capability,
Delivery, Cycle especially on
maintenance
20 Lead Availability, Cost Lead
Time, Cost
Multiskilled ratio
personnel X
shift

100%

Corrective Total maintenance Trend down Month BSI O16

Availability, Cost, Corrective maintenance man-hours
21 Lead
Compliance
NA NA
maintenance ratio man-hours X
100%
 Immediate Total maintenance Trend down, Month BSI O17
Corrective man-hours < 10
Emergency maintenance
Availability, Cost,
22 Lead
Compliance
NA NA maintenace man- man-hours X
hour ratio 100%

Number of Total number or Trend down, Month

Immediate maintenace work- < 10
Corrective orders completed
Emergency maintenance
Availability, Cost, work-
23 Lead
Compliance
NA NA maintenace work
order ratio orderscompleted
X 100%

Number of major Total number of Target 100% Quarter

assets/systems major
Availability, Cost, PM Routine
24 Lead
Compliance
NA NA
Incidence
with PM routines assets/systems

Preventive Total maintenance Trend up Month BSI O18

maintenance man-hours
Availability, Cost, Preventive man-hours X
25 Lead
Compliance
NA NA
maintenace ratio 100%

Number of PM Number of PM Target 100 Month

Availability, Cost, jobs completed X jobs scheduled
26 Lead
Compliance
NA NA PM performance
100%

Condition based Total maintenance Trend up Month BSI O19

maintenance man-hours
Availability, Cost, Condition-based man-hours X
27 Lead
Compliance
NA NA
maintenance ratio 100%

Number of work Total number of Trend up, Month BSI O22

orders performed scheduled work target 100%
Availability, Cost, Schedule as scheduled X orders
28 Lead
Compliance
NA NA
compliance 100%
 Number of Total internal 3 to 5 Month/Quarter BSI O23
maintenance maintenance man-
internal personnel hours
Availability, Cost, man-hours for
29 Lead
Compliance
NA NA Training ratio training X 100%

Number of Number of internal Target 100 Quarter/ Year BSI O24

internal direct direct maintenance
maintenance personnel
Availability, Cost, people using
30 Lead
Compliance
NA NA CMMS usage ratio software X 100%

Number of Total number of Stable Month

approved work incomplete work
Availability, orders over 3 orders
31 Lead
Compliance
NA NA Backlog age months old

Total estimated Actual available To target. Say, Month

manhours for all hours to schedule about 4 man
Availability, Work backlog outstanding work each week weeks
32 Lead
Compliance
NA NA
(man weeks) orders

Cost of replacing Total cost of 15 to 20 Quarter/ Year

Availability, Cost, obsolete items X maintenance
Plant renovation
34 Lead Compliance, NA NA
rate 100%
Capability

Total internal Total internal direct Trend up Month

Manpower direct man-hours man-hours
36 Lead Cost (Productivity) NA NA
utilisation worked X 100% available

Cumulative Total number of Trend down Month

response time of Emergency priority or stable
Response time - all Emergency service calls
Availability, Quality, Delivery,
37 Lead
Compliance
Lag
Cycle, Cost
Emergency service priority service
calls calls
 Cumulative Total number of Trend down Month
response time to Urgent priority or stable
Availability, Quality, Delivery, Response time - all Ugent priority service calls
38 Lead
Compliance
Lag
Cycle, Cost Urgent service calls service calls

Number of service Total number of Trend up or Month

calls within the service calls stable
Availability, Quality, Delivery, target response
39 Lead
Compliance
Lag
Cycle, Cost
Service level time

Cumulative Total number of Trend down Month

Fix/Make-Safe Emergency priority or stable
repair time of all service calls
Fix/Make-Safe time -
Availability, Emergency
40 Lead
Compliance
NA NA Emergency priority
priority service
service calls
calls

Number of rework Total number of Trend down Month

jobs X 100% jobs
Availability, Cost,
41 Lead
Compliance
NA NA Rework rate

Total number of None Trend down or Month

work orders stable
Availability,
43 Lead
Compliance
NA NA Work-order volume registered

Total number of None Stable Month

Availability, outstanding work
44 Lead
Compliance
NA NA Work-order backlog orders

Total number of None Stable Month

work orders
Availability, Work-order completed during
45 Lead
Compliance
NA NA
completion rate the period

Number of man- None To target Month

hours on
Availability, Cost,
Continuous continuous
47 Lead Compliance, NA NA
improvement trend improvenment
Capability activity
Data requirements to calculate and report the BSI KPIs
2009 Shire Systems Ltd
To enable the reporting of performance, input data must be compatible. The
following attributes of maintenace works must be recorded:

Work Types Corrective maintenance (Corrective + Priority 1 = Breakdown)

Preventive maintenance (at fixed intervals)
Predetermined maintenance (without a previous condition inspection)
Condition based maintenance (predictive)
Improvement maintenance (improving the dependability of an item without changing its function)
Training
Planning
Continuous improvement
Routine
Modification (changing the required function of an item)
Project

Work Priority Priority 1 (respond immediately)

Others

Failure consequence Environmental damage

Potential environmental damage
Injury to persons
Potential injury to persons

Plant up/down state Up

during maintenace
Down - failure (breakdown) times must be logged
Down - preventive maintenance
Down - predetermined maintenance
Down - condition based maintenance
Down - Shutdown (planned outage)
Down - other
System/Asset Analysed
Not analysed

Personnel resource Internal

Contractors

Trades/Employee Group Mechanical (Note: sum of all internal tradespersons can be assumed to be the direct internal personnel)
Electrical
Instrumentation
Multiskilled
Production operator

Use of CMMS Number of direct internal maintenance people using the CMMS for more than 5% of their working time

Complement Total maintenance personnel (direct + indirect) List all maintenance staff in system, divided between direct and indirect
Total number of employees (in the enterprise)
Other Maintenance KPIs & Metrics 2009 Shire Systems Ltd

Typical Typical
Indicator's Typical Applicable
Area/Group Level ID Numerator Denominator Sectors
Target Reporting Comment
Name Value Period
Total cost of maintenance X100% Net sales turnover Year
Turmover ratio

Hours the equipment was available to run Total hours in the reporting time period 96
Plant availability at capacity X 100%

Total overtime manhours worked by Total regular manhours of indirect <2 Month
Overtime rate - indirect indirect maintenance personnel during maintenance personnel during period
internal personnel period X 100%

Total emergency jobs worked X 100% Total jobs worked Month

Emergency job rate

Number of assets in the condition Total number of candidate items for 20 Quarter/ Year
Condition monitoring monitoring program X100% condition monitoring
coverage

Number of faults found X100% Number of devices surveyed <3 Quarter/ Month
Thermography survey

Number of defective steam traps found X Number of steam traps surveyed < 10 Quarter/ Month
Steam trap survey 100%
Number of approved work orders over 3 Month
Age of backlog work-
months old
orders
Number of PM jobs completed X 100% Number of PM jobs scheduled Month
PM performance

Number of overdue PM work orders at the None Month

Overdue PM end of the period

Total estimated manhours for all Actual available hours to schedule each ~4 man Month
Work backlog (man outstanding work orders week weeks
weeks)

Total number of work orders registered None Month

Work-order volume

Total number of outstanding work orders None Month

Work-order backlog
 Total number of work orders closed during None Month
Work-order completion the period
rate

Total estimated man-hours for completed Total actual man-hours for completed work Month
Man-hour estimation work orders X 100% orders
accuracy

Total actual cost of work X 100% Total estimated cost of work within 10 Quarter
Cost estimation
accuracy

Total cost of planned and estimated jobs Total cost of all jobs Quarter/ Month
Volume of estimated X 10%
work

Cost of replacing obsolete items X 100% Total cost of maintenance 15 to 20 Year

Plant renovation rate

Average age of equipment Average useful life of equipment Year

Equipment
obsolescence ratio

Number of material requisitions met from Total number of material requisitions Month
Stores issue service
stock
level
Total cost of maintenance materials Total cost of maintenance Month
Material ratio

Total cost of maintenance materials X Total cost of direct labour Month

Labour/materials ratio 100%

Number of unexpected equipment failures None Month

Plant failure rate resulting in downtime

Total number of stoppages due to failure Loading time Month

Failure frequency

Total stoppage time due to failure X 100% Loading time 0.15

Failure severity rate

Number of emergency maintenance jobs Total number of preventive maintenance + Month

Emergency X 100% emergency maintenance jobs
maintenance rate

PM tasks completed X 100% PM tasks planned Month

PM achievement

Number of modifications completed None Month

Modifications trend
 Number of modification proposals None Month
Modifications proposed registered
trend

Total direct man-hours worked None Month

Internal direct man-hour
trend

Total cost of contractors None Quarter

Contractor cost trend

Total value of parts inventories None Quarter

Inventory trend

Total internal direct man-hours worked X Total internal direct man-hours available Quarter
Manpower utilisation 100%

Total man-hours worked on shift X 100% Total man-hours worked Quarter

Shiftwork incidence

Cumulative response time of all Priority 1 Total number of Priority 1 service calls Month
Response time - Priority service calls
1 service calls

Cumulative response time to all Priority 2 Total number of Priority 2 service calls Month
Response time - Priority service calls
2 services calls

Number of service calls within the target Total number of service calls Month
Response performance response time

Cumulative Fix/Make Safe repair time of Total number of Priority 1 service calls Month
Fix/Make Safe time - all Priority 1 service calls
Priority 1

Number of rework jobs X 100% Total number of jobs Month

Rework rate

AS DEFINED AS DEFINED
Satisfaction Index