Can we control both long-term trends and short-term changes in culture and behavior? Achieved Availability 6. So, which metrics should utility executives care about? The value of having a global KPI like this in every department is that it reminds everyone of the collective responsibility for overall performance. MTBF is the average length of operating time between failures for a specific piece of equipment or component. Author, Ron Moore, suggests that process conformance can be improved through equipment reliability, proper, calibrated instrumentation, disciplined operation and quality raw material1. Data Quality. One of the main KPIs used in this category is called Mean Time Between Failure. It's necessary to change their opinion by changing your perspective. Tracking the reliability of assets is one challenge that engineering and maintenance managers face daily. When objectives are reached, you can remove these measures from the scorecard and add new transition measures. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. Warnings of pitfalls to avoid as part of the metrics process. Without them, you wouldn’t know how you were doing, much less how you can improve. The fact is that in actual practice when operations and maintenance are jointly responsible for equipment reliability the opportunity to improve is significantly increased. Interested in breaking information silos, standalone solution, and inconsistent processes in your organization? You can try us out by signing up today for a free 15-day trial. Everyone who has worked in a complex organizational structure like that required in manufacturing knows that there is a need to constantly fight against the tendency towards thinking in silos. People and Processes, Inc.P.O. Originally published in 1986, SEMI E10 Specification for Definition and Measurement of Equipment Reliability, Availability, and Maintainability (RAM) is the ‘granddaddy’ of SEMI equipment performance and productivity metrics and is one of the most widely used SEMI standards. Below are some practical steps to help facilitate a discussion on the right KPIs and approach for your organization. I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be on continuous improvement. Every part of the organization is serving the same corporate goals and objectives even though each part is playing a vastly different role and carries different responsibilities. Say the mixer shuts off every hour, while a properly functioning mixer can continuously work for 24 hours without issues. Average Uptime Availability (or Mean Availability) 3. However, in most cases, the exponential distribution is used, and a single value, the mean time to failure (MTTF) for non-restorable systems, or mean time between failures (MTBF for restorable systems are used). There are many KPIs that enable us to monitor the long-term trends in reliability and maintenance performance. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. A trend upwards in this ratio indicates that there is a problem in the maintenance and reliability performance, while a trend downwards indicates a positive trajectory. Reliability must be sufficient to support the warfighting capability needed in its expected operating environment. Since MTBF indicates the operating time of an asset, it is a metric that is closely related to the calculation of the reliability of plant and equipment, as much as metrics used to calculate the operating availability of the machine, in particular OEE (Overall Equipment Effectiveness). Everything goes wrong. Once we have the big picture firmly in the minds of every department and person in the organization, we can begin to monitor the general trends that show the effectiveness of our reliability and maintenance strategies. These KPIs help us to determine if all the little day to day adjustments and changes are actually having the desired effect over time. Everyone who has worked in a complex organizational structure like that required in manufacturing knows that there is a need to constantly fight against the tendency towards thinking in silos. Although we may be able to achieve step changes in the behavior of a maintenance and production team, the effect of these changes on the overall reliability and performance of the equipment can only be measured as a trend over time. An organization that insists on the completion of these day-to-day routines will, therefore, drive the overall performance upwards and will see the impact on the long-term trends and the achievement of the big picture KPIs. Maintenance and reliability managers must have metrics in place to identify needs for improvement. Overall equipment effectiveness (OEE) is a measure of how well a manufacturing operation is utilized (facilities, time and material) compared to its full potential, during the periods when it is scheduled to run. ... M-12/M-13 Automatic AC Transmission Outages Initiated by Failed Protection System Equipment / Automatic AC … For the unfamiliar, mean time between failures is the average length of operating time between one failure and the next of an asset. These goals are determined by the individual organization. It is vital that each function and department links themselves to the overarching objective of the whole. As long the preventative maintenance tasks are properly defined and are truly beneficial to ensure that equipment does not fail prematurely, then the completion of these tasks as per the plan will cause the long-term reliability trends to show improvement. MPU = dollars spent on maintenance / production achieved. The measures we believe are truly important are often referred to as Key Performance Indicators (KPI’s), since apparently those contain key information on performance as the wording implies. Failure rate is the number of failures per 1000 hours of operation. Reliability differs from availability by quantifying the probability that an equipment will work as intended without any failures, as opposed to just measuring the time it is in operation. MPU is a simple ratio which can be measured against benchmarks for each specific industry. Metrics are also extremely important for validating whether the maintenance team is headed in the right direction to achieve the organization’s goals and objectives. Sometimes this global goal is expressed in terms of profitability, sometimes in terms of revenue, sometimes in terms of production. Contact People and Processes to learn more about the maintenance metrics and Key Performance Indicators that your organization may be overlooking or ignoring, thereby keeping you from creating a proactive, reliability-centered culture. Departments throughout your organization, including Maintenance, Operations, Materials Management, Planning and Scheduling and Purchasing, all play vital roles and contribute to the company's bottom line but most are unmeasured. MTTR, also referred to as maintainability measures the ability to do maintenance to keep or restore equipment to a specified operating condition. Reliability measures the probability that the system will perform without failure over a specified interval under specified conditions. Convincing your executive team to purchase new software can be a challenge. Every part of the organization is serving the same corporate goals and objectives even though each part is playing a vastly different role and carries different responsibilities. 1 measure of reliability worldwide is mean time between failure." "The No. Measuring plant performance - The need for metrics standardization. It encompasses availability, performance, and quality, and when used correctly is removing waste. Simply put availability is a measure of the % of time the equipment is in an operable state while reliability is a measure of how long the item performs its intended function. These KPIs can be used to directly influence the culture of an organization and direct action can often be taken in response to these indicators. Insight into behaviors that are encouraged by the use of those metrics. However, it is possible to mask this indicator by cutting back on maintenance expenses in the short term only to incur major costs later when equipment starts to fail. Instantaneous (or Point) Availability 2. And, how can project managers ensure their teams accomplish those reliability goals? Box 460Yulee, FL 32041-0460Call us: 1-843-814-3795. Request a Demo of the Prometheus Platform. Reliability metrics are best stated as probability statements that are measurable by test or analysis during the product development time frame. Another major trend indicator is the financial KPI of Maintenance Cost per unit Production. Planned maintenance percentage (PPC) This metrics represents the percentage of time spent on … Use data-driven decision-making for equipment assets to optimize profitability, safety and compliance. Is the probability that an asset, item, or unit will perform its prescribed duty without failure for a given time in a specified environment. Adequate Level of Reliability (ALR) Metrics. The classification of availability is somewhat flexible and is largely based on the types of downtimes used in the computation and on the relationship with time (i.e., the span of time to which the availability refers). Steady State Availability 4. Another metric that relates to the duration that an equipment operates is reliability. PSA can be calculated as a percentage and should be as close to 100% as possible. equipment reliability and lower operational risks. Asset performance metrics like MTTR, MTBF, and MTTF are essential for any organization with equipment-reliant operations. EZOfficeInventory is the leading equipment management software used by companies worldwide. Inherent Availability 5. Technicians can extend the equipment’s availability by increasing its reliability. When measuring reliability, consideration must be given to the data contained in management reports. In other words, reliability of a system will be high at its initial state of operation and gradually reduce to its lowest magnitude over time. Check out our handy guide for clearing the last hurdle: executive buy-in. While general metrics work well for gauging the overall performance of any business, equipment rental firms need to go beyond general metrics to get the most accurate results. Using MTTR, you can find the average time it takes your maintenance staff to reinstate a machine to its optimal working condition following a breakdown. Major deviations in this KPI indicate that there are significant factors preventing the maintenance organization from functioning efficiently. There are literally hundreds of KPIs published that we are told should help us to measure and control our manufacturing, reliability and maintenance performance. Learn how digital permitting can reduce hazardous incidents, mitigate unsafe isolations and sub-par risk assessments, and ensure regulatory compliance. Theoretically, defects can be introduced into equipment at each of the six main phases of its life cycle: Design… Before diving into the reliability program key elements, we must understand the meaning of equipment reliability. It is vital that each function and department links themselves to the overarching objective of the whole. Corporate Metrics. ISPM helps asset-intensive industries improve equipment availability and minimize hazards with high-quality equipment reliability data. For industrial maintenance, the metric of Failure Rate is usually more relevant. If our maintenance and reliability strategies are effective and are solving the problems that cause failures in our equipment, this should show a continuous upward trend, which stabilizes at industry benchmark levels. These metrics were created by the SMRP’s Best Practices Committee using a rigorous development, review, and approval and harmonization process applying them to the SMRP's Five Pillars of Knowledge. Reliability can be characterized in terms of the parameters, mean, or any percentile of a reliability distribution. As a hypothetical example, imagine a faulty mechanical mixer. The reliability scorecard is critical to capturing project benefits and should include the following types of measures: Transition – These are temporary project measures to indicate whether reliability changes are taking place. Equipment fails. We can refine these definitions by considering the desired performance standards. Establishing metrics is essential for demonstrating the benefits of maintenance and reliability best practices. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. But you can't figure out where to start fixing your maintenance organization or how because you don't know where you're at. How should we respond to changes in the KPI we are measuring? PMSC can also be calculated as a percentage and should be as close to 100% as possible. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. Inventory Turns. Taxonomy Definitions. Specific metrics for measuring effectiveness in key areas such as maintenance planning and scheduling and MRO storerooms and material management. There are loads of metrics that are relevant and important to utilities, but three, in particular, are crucial for tracking reliability success. The three basic metrics of RAM are (not surprisingly) Reliability, Maintainability, and Availability. A simple measure for this is Production Schedule Adherence, which can be measured as: PSA = Actual Production / Planned Production. It identifies the percentage of manufacturing time that is truly productive. The last type of KPI that should be considered when building a reliability and maintenance program and measuring the performance is a KPI that measures immediate impact. What is Equipment Reliability? Reliability Consultant, Ivara Ron Thomas Director of Reliability Practices, Dofasco ... relate to manufacturing metrics. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. The goal of a main-tenance and reliability program is to deliver a proper balance of maintenance activities — primarily those aimed at … All of these factors can be immediately actioned in order to resolve the problem. Another short-term KPI is the measure of completion of preventative maintenance tasks – Preventative Maintenance Schedule Compliance: PMSC = Completed PM tasks / Planned PM tasks. Employees gripe. People often confuse reliability and availability. Allocating equipment and inventory to selected employees or teams; Predicting the budget for future equipment and maintenance costs; Five metrics you can use to evaluate Asset Reliability at your plant are: 1. Requirements for a Successful Reliability Team. Maintenance and Reliability for Managers - 4 Part Series, Maintenance and Reliability Technician Core Concepts, Maintenance Storeroom and Materials Management, Maintenance and Reliability Best Practices. It is important as a reliability and maintenance professional to focus daily attention on the short-term KPIs in order to drive the behavior and cultural change that is needed in an organization. If this doesn’t happen, then the short-term KPIs should be reviewed to ensure that the right actions and behaviors are being measured and controlled and changes should be made as necessary. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). Reliability = V x 100 W The frequency with which the machine breaks down and disrupts production Data Which ones do we focus on and why? © 2020 Prometheus Group All Rights Reserved. It is calculated by dividing a specified period of operating hours by the number of failures. The Society for Maintenance and Reliability Professionals (SMRP), developed standard definitions for metrics used in industry. Reviews of the bill of materials for maintenance tasks can improve the planning data. You know maintenance needs better software and you’ve found the perfect solution. For utility companies, reliability means success. Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. The purpose of most equipment in manufacturing is to support the production of However, the result of this change may only be noticeable in the reduction of failures over a period of weeks and months. Considerations of reliability must support both availability metrics. One of the challenges of building and maintaining an effective reliability and maintenance strategy for any manufacturing organization is the task of sifting through the many proposed measures of success to come up with a KPI matrix that is relevant, easy to understand and actually drives the behaviors and performance in the right direction. Maintenance metrics matter. Equipment Metrics and Benchmarking 5 5 1. It is the big picture that all of our own individual contributions and department goals are helping to achieve. One example of a corporate-level KPI is the measure of how well the manufacturing facility performs in terms of meeting the planned production that is laid out for it by the business. The KPIs that we are looking for here are ones that measure trends over a longer time frame. Planners pad estimated work hours for orders in order to maintain schedule compliance, so you don't assign enough work to technicians as a result. Integration with other data management systems, Proper configuration and utilization of data fields in support of best practices, Utilization of metrics and Key Performance Indicators (KPIs), Developing effective metrics to show and drive continuous improvement, Training in managing and measuring with Key Performance Indicators (KPIs) to show progress and sustain proactive behaviors, Optimizing use of the CMMS/EAM reporting tools, Forming a data collection system that supports the dashboard, Leveraging trending analysis to your advantage. Once these short-term indicators are under control, the long-term trends should move in the right direction too. Reliability uses many metrics for evaluating equipment and systems. The original metric, Mission Reliability, answered the question of figure 4. Using the wrong maintenance metrics—or worse yet none at all—can cause or contribute to problems like the following. This could be due to things like breakdowns in equipment or a lack of availability of spares to execute the planned work. Keeping an eye on the big picture will help to ensure that everyone is on the same page, knowing that the collective effort of every individual and department is leading to the achievement of the corporate business goals and performance. While the availability of the faulty mixer may still be quite high if opera… Equipment reliability assures that subsystems and components function as intended without failure for desired periods during their design life. Reliability is the probability that a system performs correctly during a specific time duration. You can use our product to measure the performance metrics of your equipment and keep track of your assets more efficiently! The financial impact of unexpected equipment failure can be costly, as AK Steel Corp. shared recently. A key short-term KPI is the measure of compliance with the maintenance plan – Maintenance Schedule Compliance: MSC can be calculated as a percentage and should be as close to 100% as possible. As a result, there are a number of different classifications of availability, including: 1. Investigations into the causes of failures can help prevent breakdowns. Overall Equipment Effectiveness (OEE). However, new technology only enables an ineffective maintenance program to be more efficient at being ineffective. Here you can focus on three main areas for which you can define additional KPIs: assets, operational and customers. Reliability may be Equipment Metrics and Benchmarking 5 5 1. The reliability scorecard is critical to capturing project benefits and should include the following types of measures: Transition – These are temporary project measures to indicate whether reliability changes are taking place. Monitoring the long-term trends will show whether these daily activities are having the desired effect on the performance and highlight where some tweaking is required. For example, a radical improvement in the management of lubricating oils for rotating equipment can be achieved with the introduction of a new system of sampling, testing, and flushing. dated equipment with the latest technology. Your Computerized Maintenance Management System (CMMS) or Enterprise Asset Management (EAM) system provides useless information or you don't use data properly. Availability, also known as operational availability, is expressed as the percentage of time that an asset is operating compared to its total scheduled operation time. Only by tracking these critical KPIs can an enterprise maximize uptime and keep disruptions to a minimum. Sometimes this global goal is expressed in terms … Industry Data. 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