October - Library - Central Queensland University

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Proactive Maintenance Metrics
PM and PdM Schedule Compliance
The goal is to determine the portion of PM and PdM work orders that were completed on or before the due date and had labor
c h a rges posted to them. First determine the number of PM and PdM work orders that were completed by the due date. Also a
reasonable amount of labor has to be charged to the completed PM and PdM work order. Reduce the number of PM’s completed
on time by the number completed on time without labor charges. The PM Compliance percentage should be 95% or more, and the
PdM Compliance percentage should be 100%.
The metric are calculated as follows:
# of PM’s completed on time with a reasonable amount of time charged
PM Schedule Compliance = --------------------------------------------------------------------------------------- X 100%
Total number of PM’s due during the period
# of PdM’s completed on time
PdM Schedule Compliance = -------------------------------------------------------- X 100%
Total number of PdM’s due during the period
Proactive to Reactive Ratio
This metric denotes the portion of maintenance work dedicated to preventing or mitigating equipment failures as opposed to work
dedicated to restoring failed equipment to operation. The numerator is the sum of the craft hours consumed by PM and PdM work
plus the craft hours consumed for planned corrective work that originates as a direct result of the PM and PdM activities. The
denominator is craft hours consumed by all other unplanned maintenance work (i.e. breakdowns, emergencies, and call-ins for
maintenance). The world-class maintenance organizations have a ratio of 7:1.
The metric is calculated as follows:
PM & PdM Craft Hours + Planned Corrective Work Hours
Proactive to Reactive Ratio = --------------------------------------------------------------------------------------------
Craft Hours spent on Breakdown, Emergencies, Call-ins, and Other Unplanned Work
Overall Vibration Level
A key indicator of the health of rotating equipment is the overall vibration level of the equipment in the vibration analysis program.
This metric needs to be re p o rted on a monthly basis by the Vibration Analyst in chart form. It should be re p o rted for all the equipment
in the vibration analysis program plant wide, and by individual production units if the plant is broken up into such units. The vibration
analysis software should allow this metric to be easily generated. For world-class organizations the overall vibration level across
the plant is less than 0.09 inch per second in velocity.
Percent of Maintenance Performed by Operators
In the world of Total Productive Maintenance (TPM) the concept is to have operators perform minor adjustments and maintenance
activities. This metric denotes the portion of the total maintenance related man-hours that are re c o rded by operators in the
performance of maintenance related tasks within a given period.
The metric is calculated as follows:
Operator Maintenance Hours
% Operators Maintenance Work = -------------------------------------------------------------------- X 100%
Maintenance Craft Hours + Operator Maintenance Hours
Failure Analysis Percentage
This metric assumes that failures which stop or slow down the production process to some predetermined threshold receive some
type of formal failure analysis. An example of an established threshold would be a policy that calls for failure analysis to be perf o rm e d
whenever there is an equipment issue that stops production for over 30 minutes.
Select an appropriate time period and compare the number of failure analyses perf o rmed during the period with the number of
equipment related process interruptions that exceeded the established threshold during the period.
The metric is calculated as follows for the given period:
# of Failure Analyses Performed
Failure Analysis % = -------------------------------------------------------------------------------------- X 100%
# of Equipment Related Process Interruptions that exceeded the threshold