Planned Maintenance Percentage (PMP) is a maintenance key performance indicator (KPI) that evaluates the effectiveness of your planned maintenance by comparing your planned maintenance hours against the actual hours spent on maintenance activities. PMP helps you measure the current effectiveness of your planned maintenance and provides a benchmark for improvements.
Ultimately, the purpose of tracking PMP is to:
- Assess the health of your preventive maintenance program
- Reduce reactive maintenance
How Do You Find Your Planned Maintenance Percentage?
PMP consists of two factors:
- Planned maintenance time
- Overall maintenance time
Time is formulated in hours and is based on a consistent period of time, be it weeks, months, or years.
The formula is:
Hours of Planned Maintenance Tasks / # of All Maintenance Tasks
To ensure accuracy, you must document all of your facility’s maintenance hours as precisely as possible. A computerized maintenance management system (CMMS) simplifies the process of recording maintenance hours, while also reducing data entry errors.
The formula for PMP is fairly simple; improving this metric is often the greater challenge.
What Is Planned Maintenance?
Planned maintenance is simply maintenance tasks that have been scheduled or put in a queue. Planned maintenance can be time based (such as tasks that need to be done annually) or usage based (tasks that need to be done after a certain amount of runtime, for example). Unplanned maintenance refers to any maintenance done in response to a failure or potential failure. This unscheduled maintenance is about preventing, or responding to, breakdowns.
In the maintenance space, there are always many decisions to make. Using data to optimize those decisions — such as adjustments to schedules or allocation of resources — can improve your bottom line. PMP turns data points into a measurement that offers you insights.
Tracking your planned maintenance percentage can help you identify trends over time as well as:
- Broken workflows
- Areas of inefficiency
- Causes of resource failure
Watching your planned maintenance percentage over time can help you plan, control costs, and extend the life of your equipment.
What Is a Good Planned Maintenance Percentage?
Knowing how you compare to others can help you gauge the level of your PMP. According to best-in-class standards, the goal is to have a planned maintenance percentage of 85% or higher. When you calculate and track your PMP, you can set benchmarks, draw comparisons, and work toward continuous improvement.
If your PMP is low, you can research the root cause of failures, pinpoint inefficiencies, and find and fix broken processes.
PMP starts you on the path to maximizing the strengths and identifying the weaknesses in your maintenance program. Cutting down on wasted labor and parts can help your organization meet its goals.