Maintenance is a very essential activity to run a manufacturing organization. To improve equipment effectiveness performance measurement is very important. A part from machine downtime point of view maintenance and production team will be responsible because the role of production team is to take an output from machine with maintaining machine in good condition and the role of maintenance team is to resolve the problems for machine breakdown. In a broader view analysis overall machine operator is very much responsible for activity happened with machine.
In this article we detail review about different key performance indicators related to machine maintenance activity as well as how to measure this KPI.

Operational KPIs

Machine Downtime

Machine downtime is generally measured in hours; minutes or seconds individually machine wise. Each and every organization is structurally focused on to minimize machine downtime and improve performance of equipment. Maintenance department is play a key role to minimize machine downtime with the taking corrective action as early as possible.

Mean time between failure (MTBF)

MTBF is a one of the very important KPI for measuring maintenance team performance. It measured based on average gap between consecutive breakdowns. It’s very helpful KPI and many of the organization is used to measure performance. Organization is structurally focused to increase the value of MTBF.

MTBF = Machine Uptime / Numbers of Breakdown.

Mean time to repair (MTTR)

MTTR is represent performance of downtime and measure how maintenance team effectively resolve the breakdown. For total productive maintenance implementation MTBF and MTTR is a very much useful tools to measure, monitor and improve performance of equipment. Maintenance team is responsible for minimize the value of MTTR.

MTTR = Machine Downtime / Numbers of Breakdown.

Downtime to uptime ratio

Downtime to uptime ratio represent average percentage of equipment downtime with comparison of equipment uptime. Organization is focused to minimize downtime to uptime ratio structurally.

Downtime to uptime ratio = Downtime / Uptime

Trend of Emergency breakdown

Emergency breakdown is basically occurring without any indication. When emergency breakdown occurs, production is suddenly stop. Structurally measure and monitor the trend of emergency breakdown is very much important. For minimize the emergency breakdown generally each and every organization is schedule for pre-planned maintenance activity which is called preventive maintenance. Sometimes emergency breakdown trend measure with comparison of total downtime, uptime or total available time of equipment.

Percentage of PM adherence

In total productive maintenance practice, preventive maintenance is basically pre-planned activity. Based on machine downtime trend and emergency breakdown trend most of the organization plan preventive maintenance schedule accordingly. So in percentage of PM adherence KPI measure the accuracy of preventive maintenance as per planned.

Percentage of PM adherence = Numbers of actual PM attempts as per planned / Total PM attempts planned

Asset Performance (OEE)

Maintenance team also focused to review performance of equipment with the help of overall equipment effectiveness. For maintenance point of view availability improvement play a vital role. If the trend of machine downtime decreases its directly impact on machine availability improvement. Review below attached calculation of OEE.

Asset Performance (OEE) = Availability % * Performance % * Quality %.

% of downtime due to spare unavailability

Effective way spares inventory management is also very important for maintaining minimum downtime trend. For improvement point of view separate downtime activity in a different category. Review below attached formula for this KPI measurement.

% of downtime due to spare unavailability = (Downtime due to spare unavailability / Total downtime) * 100

Financial KPIs

Per unit maintenance cost

For each and every individual activity financial performance measurement is very much important. So, in maintenance department also measure the financial performance with total maintenance cost occurred for running equipment. Review below attached formula for per unit cost.

Per unit maintenance cost = Total maintenance cost / Total quantity produced

% of Preventive maintenance cost

Preventive maintenance cost is measure with the respect of total maintenance cost. Review below attached formula for calculation.

% of preventive maintenance cost = (Preventive maintenance cost / Total maintenance cost) * 100