If there’s one potential blindspot in the PM compliance calculation, it’s late PMs. The MTTR … This can be a problem as it allows delayed tasks to fly under the radar and gives you a false sense of security about the success of your operation. Planned Maintenance Percentage (PMP) measures how much time is spent on planned versus... Preventive Maintenance Compliance. Each scheduled training session helps a person’s body get closer to the finish line. Enter the 10% rule. PM compliance doesn’t account for reactive maintenance tasks that are scheduled as these are often one-time jobs. Preventive maintenance compliance. These changes make it easier for technicians to do their jobs faster, which means fewer PMs are left on the sidelines. There are two problems maintenance managers can face. When a task isn’t making an impact, technicians notice and tend to bypass it. Running a marathon is gruelling work. It is a variation of the metric called “planned maintenance percentage” that’s discussed below. Only regularly scheduled, preventive maintenance tasks should factor into your measurement. A big part of implementing a successful preventative maintenance program in your business is understanding maintenance failure data, and effectively using them as KPI's. Skipped PM Percentage. The first of these is not enough information to keep the business powering along at optimum performance. The question is, how do you avoid falling into this trap and stop late PMs from masquerading as a job well done? For example, let’s say you’re measuring PM compliance for a three-month period. Preventive Maintenance Compliance Monthly report showing the number of vehicles scheduled for PM compared to number of PM’s actually completed, where applicable. Mean time to repair (MTTR) MTTR is the measure of the repairable items maintainability. 2. maintenance performance through the use of performance metrics. This month, we’ll focus on a set of metrics that address performance levels in the maintenance organization: Planned and Scheduled Work Completion Rate, Maintenance Overtime, Preventive Maintenance Hours as a Percentage of Total Work and Emergency Repairs as a Percentage of Scheduled Hours. Leverage the cloud to work together, better in the new connected age of maintenance and asset What does PM compliance mean for maintenance? World class unscheduled downtime: 10% or less Equipment availability: This is a measure of how often a piece of equipment is available for its intended purpose. Therefore, it’s a good idea to work with the 10% rule, which factors in late PMs and saves you from turning a blind eye to chronically late tasks completed just before the time cutoff. Machine Downtime Versus Uptime. On first glance, the formula doesn’t account for late PMs or calculating how late they were. One way to do this is to use another maintenance metrics: Scheduled maintenance critical percent (SMCP). KPIs can be very specific to an individual's activity or broad enough to measure an entire plant's performance. Your maintenance should too. One of the main goals of preventive maintenance is to catch issues as soon as possible. Having a preventive maintenance plan is useless if it’s not followed. These tasks won’t fall off the radar and cause not only will your PM compliance improve, but so too will reliability, availability, and production. The colors in the Preventive Maintenance Compliance metric indicate benchmarks for a healthy system. For example, you may have had 50 PMs scheduled last month. If they are being completed infrequently, look into if they even need to be completed at all. For example, let’s say you want to figure out your PM compliance for last quarter. In the example above, the 60-day PM task, it would only be considered compliant if it’s completed within six days of its due date. Fleet Maintenance Metrics Performance Metrics are a tool we use to examine our function as a fleet management team. This article will discuss 5 key metrics & failure data collection procedures that you need to consider, how to calculate them, and what benefits they offer for cost reduction and optimized efficiency. PM compliance = 0.825 x 100. An organization’s preventive maintenance schedule is similar. This does not apply to GSA vehicles maintained off–site and where the customer delivers the vehicle for service. It was learned from the survey results that the maintenance performance monitoring is integral part of the overall maintenance management system at all the utilities that responded to the survey. Eliminating unnecessary PMs can free up resources for other work that will make more of an impact. Welcome to our series of blog posts about maintenance metrics. Asset maintenance – Planned Maintenance Percentage (PMP), Schedule Compliance, Mean Time Between Failure (MTBF) Safety and compliance – Number of Reported Accidents and Incidents, Lost Time Injury Frequency Rate (LTIFR) Asset performance – Overall Equipment Effectiveness, Asset Uptime; Downtime – Production Uptime Percentage, Equipment downtime They can be leading or lagging, simple counts or complex calculations. Here’s what your PM compliance calculation would look like: PM compliance = 165 completed PMs ÷ 200 scheduled PMs x 100. The more training sessions they miss, the greater the chance of failure. management. Thanks to the 10% rule, late PMs can fall outside the compliant category, even if they are eventually completed. There is an … This post outlines everything you need to know about preventive maintenance compliance: What is PM compliance, the PM compliance formula, why it’s important, and how to improve it. In that time frame, there’s a PM that must be done every 60 days. Poor PM compliance can be a symptom of bigger issues plaguing your maintenance team. strategies. Measuring Downtime as a KPI, can help Maintenance Department t… Eight questions shaping the future of maintenance. PM compliance doesn’t account for reactive maintenance tasks that are scheduled as these are often one-time jobs. Preventive maintenance keeps the machine running longer time as shown in figure (1) without breakdown by optimizing machine operating condition which leads to prevent unplanned breakdown in the production line (Preventive maintenance, 2018). PM compliance = 82.5%. In consequence a similar attempt has been made to develop maintenance performance metrics in the next section. However, a fractured preventive maintenance strategy can actually open the door to more breakdowns. Preventive maintenance compliance (PMC) measures the percentage of preventive maintenance tasks (PMs) that have been completed on schedule in a specified time period. But this plan won’t be successful if the trainee doesn’t stick to it. To calculate your PM compliance for the month, you would divide 40 by 50 and multiply the result by 100. That’s a big risk to take with a potentially important task, but the PM compliance formula wouldn’t register the magnitude of this mistake. Analyze your data, find trends, and act on them fast, Explore the tools that can supercharge your CMMS, For optimizing maintenance with advanced data and security, For high-powered work, inventory, and report management, For planning and tracking maintenance with confidence, Learn how Fiix helps you maximize the value of your CMMS, Get best practices, helpful videos, and training tools, How a leader in the oil industry used Fiix to slash inventory costs, Discover guides full of practical insights and tools, Read how other maintenance teams are using Fiix, Get the latest maintenance news, tricks, and techniques. Maintenance Metrics Inspection Results. The black triangles show where your system is in relation to those benchmarks. The PMC formula doesn’t take into account the number of late PMs or how late they are. That’s why you should regularly audit your PMs to ensure they are done at the optimal frequency. Join over 14,000 maintenance professionals who get monthly CMMS tips, industry news, and updates. Fiix® is a registered trademark of Fiix Inc. Get the Executive's Guide to Digital Transformation and find out how. Get your blueprint for building the maintenance team of tomorrow, today. The difference between a successful organization and a s… The most common way to measure schedule compliance is by tracking your preventive maintenance jobs. Preventive maintenance is a crucial strategy for reducing downtime. The 10% rule isn’t an iron-clad law of maintenance — some small issues will most likely fall through the cracks. Knowing where your resources and processes are lacking can help you find a solution and get your PMs back on schedule so critical assets get the attention they deserve. That’s a substantial amount of time and money dedicated to these tasks. can actually open the door to more breakdowns. The 10% rule says that completed PMs are only considered compliant if they are finished within a 10% time frame of their scheduled maintenance interval. Planned versus unplanned maintenance. If you’re allocating resources to a task that isn’t relevant anymore, these resources will go to waste and your metrics will be skewed. Developing and Implementing Metrics for Maintenance Planning and Scheduling Metrics We often call the Planning and Scheduling group the "hub" of maintenance because it determines the efficiency of your craftspeople by eliminating the avoidable delays of waiting … Having a good Maintenance Strategy in place, can reduce downtime by more than 30%! Take your business to the next level with PM compliance. "We want 100% compliance, but what typically happens is that only about 60% are done, and only 20% to 30% are done right," Shiver says. But how do you know if your team is effectively executing its preventive maintenance program? facility morale. Compliance teams often use metrics and KPIs as risk-assessment tools and measurements of compliance success. If the task falls outside the 10% period, it is not eligible to be included as a completed PM in your PM compliance calculation. To calculate the preventive maintenance compliance rate, the following steps must be followed: Define a preventive maintenance plan and a task list for each piece of equipment Carry out the preventive maintenance plan during a defined period Calculate the percentage of preventive maintenance work orders completed on time Getting to the bottom of these issues can go a long way to improving PM compliance, getting your preventive maintenance program back on track, and, ultimately, improving asset reliability across the board. Organizations can use parts, people, and money more efficiently while maximizing uptime. The world has changed. To calculate PM compliance, first start by dividing the total number of completed preventive maintenance work orders by the total number of scheduled work orders within a defined period. You don’t just wake up one morning and run 26 miles. Keeping track of PM compliance is a good way to avoid being penalized during an audit and can be a way to prove to auditors that your organization is working by the book. Downtime is incredibly costly for any company which has assets. Organizations can leverage MTBF to determine preventive maintenance tasks such as rate of inspections, or introduce preventive actions such as lubrication, greasing and calibrations. Shifting production demands, new equipment, better parts, improved processes, and advanced technology may render a PM obsolete. Back to maintenance Preventive maintenance programs have been shown to reduce downtime by up to 20% annually, and tracking PMC is one way to determine if a PM program is working well or not. Create a reliability and maintenance policy with an improvement plan. Compare the best Small Business Preventive Maintenance software of 2020 for your business. Each PM task is meant to weed out any potential problems with assets so they can stay healthy and operating at their best. Figure 2.2: This figure illustrates how many organizations perform a monthly (30-day) preventive maintenance strategy applied to a specific component. There are different metrics that maintenance and production teams use to track the reliability of equipment. However, it’s one of the best methods for establishing a baseline to weed out dangerously late PMs and makes PM compliance a more accurate view of your team’s success. Conducting a PM compliance analysis helps maintenance teams target areas of weakness in their preventive maintenance program. However, the team didn’t get around to completing that PM until 15 days after its initial deadline. Your PM compliance would be 80%. Intuitively, most everyone understands that there is value in maintaining assets in a reliable working state. Analyze your data, find trends, and act on them fast, Explore the tools that can supercharge your CMMS, For optimizing maintenance with advanced data and security, For high-powered work, inventory, and report management, For planning and tracking maintenance with confidence, Learn how Fiix helps you maximize the value of your CMMS, Get best practices, helpful videos, and training tools, How a leader in the oil industry used Fiix to slash inventory costs, Discover guides full of practical insights and tools, Read how other maintenance teams are using Fiix, Get the latest maintenance news, tricks, and techniques. Auditors often look at a facility’s PM program its level of compliance. This does not apply to GSA vehicles maintained off–site and where the customer delivers the vehicle for service. PM compliance = # of completed PMs ÷ # of scheduled PMs x 100. 4. Copyright © 2020. Tracking PM compliance makes it clear where the gaps are in your strategy. Your PM compliance score is a thermometer that measures the health of your maintenance processes, from your inventory purchasing methods to the way you train and provide resources technicians. DEVELOPING A BASIS OF MAINTENANCE PERFORMANCE METRICS As explained in previous section it is necessary to identify the It is calculated by dividing the number of tasks performed by the number of planned tasks and multiplying it … PM compliance is one tool maintenance teams can use to track the effectiveness of their preventive maintenance program and the efficiency of their processes. Establishing mobile maintenance is one way technicians can access resources easier and finish jobs quicker. Note: The number of planned WOs could be larger than the number of PM WOs because corrective maintenance … PM compliance is one tool maintenance teams can use to track the effectiveness of their preventive maintenance program and the efficiency of their processes. Calculating PM compliance can also tell you if relevant PMs aren’t being completed consistently. PMs are there for a reason — to defend against failure. There were 200 PMs scheduled during the last three months and your team completed 165 of those PMs within an acceptable time frame (remember to apply the 10% rule). All Rights Reserved, A look at the tools that empower your maintenance team, Manage maintenance from anywhere, at any time, Track, control, and optimize asset performance, Simplify the way you create, complete, and record work, Connect your CMMS and share data across any system, Collect, analyze, and act on maintenance data, Make sure you have the right parts at the right time, AI for maintenance. Preventive maintenance system can be costly and spending time but the The more PMs that are missed, the more likely that piece of equipment will fail. Measuring and improving PMC helps to increase accountability and fine-tune the work order process. Multiply the result by 100 to find the PM compliance percentage. Metrics should be aligned with the current state of the organ… Click here to see the rest of the series. Knowing how to use SMCP effectively can help your maintenance team target important PMs. However, they should follow a few simple ground rules to ensure quality input. Debates ensue over what is a KPI, what is a Metric, who should set KPIs and based on what, when and how they should be reviewed, the balance between leading and lagging indicators, the list goes on. By tracking this KPI and the associated metrics (downtime, uptime and number of failures) preventive maintenance schedules can be optimized. But PMs only work if they are being optimized, and completed consistently and on time. The more PMs that are missed, the more likely that piece of equipment will fail. Copyright © 2020. Schedule compliance is a maintenance metric that measures the percentage of work orders completed on or before the due date over a given period of time.. How do I improve schedule compliance for my preventive maintenance? PM compliance is also an important tool when preparing for audits. Join over 14,000 maintenance professionals who get monthly CMMS tips, industry news, and updates. Preventive maintenance accounts for 60% of all maintenance in a typical organization. Compliance KPIs can be implemented as an early warning system to detect potential compliance issues, and help the business move quickly to implement controls or other measures to prevent regulatory action, bad publicity and/or employee dissatisfaction. All Rights Reserved, A look at the tools that empower your maintenance team, Manage maintenance from anywhere, at any time, Track, control, and optimize asset performance, Simplify the way you create, complete, and record work, Connect your CMMS and share data across any system, Collect, analyze, and act on maintenance data, Make sure you have the right parts at the right time, AI for maintenance. One method is tracking preventive maintenance compliance (PM compliance). The scope and completeness of the maintenance Get your blueprint for building the maintenance team of tomorrow, today. It’s important that you don’t include every maintenance task into your calculations. Each minute a critical asset is unavailable, especially in … It represents maintenance work that … Your maintenance should too. You can’t always avoid these situations, but you can make PMs easier so they are done faster and PM compliance can rise. Backlog is inevitable, but there are ways to manage it so its impact on PM compliance and your facility as a whole is mitigated. The biggest reason for missed PMs is pretty straightforward—there’s just not enough time or resources to go around. Find the highest rated Small Business Preventive Maintenance software pricing, reviews, free demos, trials, and more. Calculating preventive maintenance compliance is one way to allocate resources more effectively, improve health and safety, and ensure assets aren’t suffering needless downtime. “This is how we’ve always done it,” can be the seven most damaging words uttered by a maintenance manager…Eliminating unnecessary PMs can save a lot of time, money, and effort while boosting PM compliance and facility morale. The world has changed. SMCP allows you to see which late PMs should be done first by measuring their impact on the business. Improving PM compliance can go a long way towards strengthening the reliability of your entire organization and making sure none of your valuable time and money goes to waste. Planning sits at the center of … 1. It’s important that you don’t include every maintenance task into your calculations. Once you can identify which important tasks are being skipped, you can begin to find out why. You can’t blame someone for skipping a pointless job to work on one that’s higher-priority. Work order backlog. PM compliance is most effective when used to improve a facility’s preventive maintenance program with the goal of reducing downtime. Improving your PM compliance can have a huge ripple effect that touches not only maintenance, but the well-being of the business at its highest level. If your company already has a preventive maintenance plan, it is the Preventive Maintenance Compliance (PMC) that tells us if your preventive maintenance plan is efficient or still needs some adjustments. A world-class level is 90% planned. Then, multiply the result by 100. According to Vanson Bourne research, Average downtime costs 240.000 US dollars per hour according to decision makers in Field service and Service management. Preventive Maintenance Metrics Planned Maintenance Percentage. The task would be marked as complete and raise your PM compliance score. PM compliance also only accounts for preventive maintenance tasks and not reactive maintenance tasks, regardless of if they are scheduled or not. From a driver regularly changing the oil in his car to the hydraulic technician ensuring the system pressure is consistent on a 3,500-ton metal-forming press, there are innumerable tasks being performed worldwide that keep plant operations going and assets performing. Fiix® is a registered trademark of Fiix Inc. This is usually measured in hours or days. Unscheduled downtime: This results from unforeseen breakdowns and requires work orders that are not scheduled out in advance. PMC, along with scheduled maintenance critical percent (SMCP), and planned maintenance percentage (PMP) allow you to optimize maintenance schedules, use resources effectively, and ensure assets are as reliable as possible. Reasons can include everything from a breakdown somewhere in the work order process to a lack of spare parts or a shortage of labour. It takes months to train. To calculate PM compliance, divide the total number of completed PMs in a given period by the total number of scheduled PMs within that period. The 10% rule of preventive maintenance simply states that: A time-based PM must be accomplished in ten percent of the time frequency or it is out of compliance. maintenance and such type of metrics is a great challenge for the researcher. Every hour, day, or week that a PM is delayed raises the chances of a problem going unnoticed, growing worse, and resulting in a breakdown. There’s only so much time in a day, and an emergency can eat up a lot of that time, pushing routine tasks into the background. Only regularly scheduled, preventive maintenance tasks should factor into your measurement. That is stressful enough, but the second issue also has its own set of dilemmas – too much information. 70% of the companies' lack awareness of which assets require maintenance which leads to unpredictable failures and costly downtime. If you are looking to benchmark your maintenance operation, world class PM compliance is considered to be 90%. “This is how we’ve always done it,” can be the seven most damaging words uttered by a maintenance manager. Without adequate reporting, you are basically flying blind. ... Poor inspection results suggest lacking preventive maintenance practices, but they may also reveal poor driving habits or issues with the reliability of a specific model of a vehicle. Preventive maintenance compliance (PMC) measures the percentage of preventive maintenance tasks (PMs) that have been completed on schedule in a specified time period. Maintenance KPIs – the Good, the Bad and the Ugly Why KPIsThe theory and context behind KPIs is well established, a quick internet search leads to pages of results. Metrics should be easily connected to the business value that strong performance will deliver. Preventive Maintenance Compliance Monthly report showing the number of vehicles scheduled for PM compared to number of PM’s actually completed , where applicable. Tracking PM compliance can ensure those resources are being used effectively. Better training and improved troubleshooting procedures are also worthwhile investments to reduce the time it takes to perform PMs. Each PM task is meant to weed out any potential problems with assets so they can stay healthy and operating at their best. Failing to comply with critical PMs can be a serious penalty that could lead to fines. Late PMs can be just as bad as missed PMs. You dedicate a lot of resources to your preventive maintenance program. Data is collected from our fleet management software, and other sources, and translated into charts and graphs that illustrate trends, the … Your team completed 40 of those PMs, while 10 did not get finished. If an asset breaks down and a repair is scheduled for the next day, this task is not included in your calculation for PM compliance. Discovering which tasks are being missed and eliminating these unnecessary PMs saves a lot of time, money, and effort while boosting PM compliance and making technicians feel valued. ... compliance and performance metrics easily and efficiently. U… It’s especially helpful when preparing for audits and identifying long-term solutions to recurring problems as it can tell you if improper work is causing easily avoidable issues.
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