What are World-Class Maintenance Performance Metrics?

In the maintenance world, there is a progressive hierarchy and general thinking that needs to be followed in order to achieve the best results. This methodology is called “world class maintenance.

While performance metrics are the goal, the progressive order starts with frequency histograms, then moves to mean-time calculations to condition monitoring, and then ultimately predictive algorithms. Every one of these is usually progressively more expensive, whether in terms of how data is collected from a labor force, or whether there are automated collection systems set up.

“It can’t be that simple, you might argue, but psychologists and economists will tell you it is. Human beings adjust behavior based on the metrics they’re being held against. Anything you measure will impel a person to optimize his score on that metric. What you measure is what you’ll get. Period.”

Dan Ariely, Harvard Business Review

Developing frequency histograms is the cheapest and easiest thing you can do with a CMMS. What are the top 10 things that are going on in my factory? Which asset has the most interruptions or unplanned events? Are any departments struggling with the most downtime? These are all forms and types of frequency histograms.

performance metrics on a CMMS dashboard

Types of Maintenance KPIs to Use

Frequency Histograms → Mean-time Calculations → Condition Monitoring → Predictive Algorithms

Mean-time between failures and the mean-time to repair are fairly common metrics that most people are familiar with.

Read more: MTBF, MTTF, MTTR: Powerful Maintenance KPIs

condition monitoring which provides performance metrics

Condition monitoring gets a little bit more expensive. Teams must collect and analyze data before software determines a condition. For instance, data can be tomography, acoustic emission, or vibration analysis. There is certainly some effort and money spent on collecting information if you have the right equipment to do it.

Similarly, the last step from there is the predictive algorithms, which means taking the condition monitoring data and running it through a series of calculations. If organizations skip a level of this hierarchy, they will not achieve the fullest result.

Begin Working with Performance Maintenance Metrics

Above all, building your maintenance department to “World Class” status takes effort and planning.

Start With The End In Mind – What Does Success Look Like?

  • What data or reports would make life easier?
  • Is there information the boss consistently ask for?
  • Have you calculated the current PM:CM ratio?
  • Did you determine type of PM:CM ratio does the business need?
  • Are there any current maintenance budget busters?
  • What is the on-time PM performance or compliance?

Some Basic Startup Maintenance Metrics

Lagging Indicators – Performance Measurements

  • CM to PM ratios (World Class = 1 to 4)
  • MTBF (Mean Time Between Failure)
  • MTTR (Mean Time To Repair)
  • MTBI (Mean Time Between Interruption)
  • Top 10 Analysis (Cost, Frequency, Duration)

Leading Indicators – Performance Drivers

  • PM on-time Compliance
  • Estimates vs. Actuals
  • Percent Failures undergoing RCA

Performance Metrics of Assets

At the minimum, an asset structure must include the following:

  • Parent Grouping
  • Child Specific Assets
  • Child Miscellaneous Asset – Only one per parent
Asset metrics being recorded by vibration sensors

Work Order Performance Metrics

The Work Order serves two critical purposes and must contain the following elements for each purpose:

Work to be completed:

  • Child Asset – Mandatory
  • Parent Asset Information
  • Work Type – Planned / Unplanned
  • Work Status – Open / Closed
  • Primary Craft
  • Required Craft & Hours
  • Material Needed
  • Safety Information / Requirements
  • Due Date

Work completed:

  • Actual Labor Used
  • Date job was completed
  • Time it took to complete this job
  • Comments on significant deviation
  • Parts actually consumed
  • Problem code

Basic CMMS Data Collection for Performance Metrics

woman thinks about storeroom logistics
Credit: Adobe Stock

Start out by identifying which asset you want to remotely collect data from. After that, set up a data collection device to get data from that device into a local server. Next, the local server will run the algorithm from the condition monitoring max/min levels and then send a signal to the automated work order system. This triggers an alarm which will then auto-generate a work order for investigation from the CMMS system. That will allow the work order to be tracked for completion. Then, the investigation discovers whether the asset is in a true condition for repair. After that, you will be able to plan and schedule the repair.

Performance Metrics Summary

  • Begin with the end in mind!
  • Set up asset hierarchy
  • Create supporting fields in work order form
  • Monitor the work order process
  • Monitor the asset performance
  • Prioritize asset improvement areas
  • Move up the P-F curve

To learn more about how to make your maintenance operations world-class, please sign up to get a demo from one of our friendly and knowledgeable Customer Success Managers.

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