SMRP Best Practice Metrics
Workshop
Measuring Asset Reliability
SMRP Headquarters
1100 Johnson Ferry Road, Suite 300
Atlanta, GA 30342 USA
www.smrp.org
Copyright © 2014 Society for Maintenance & Reliability Professionals
Best Practices Committee- Metrics Workshop
© 2014 SMRP
Page 2 of 14
Best Practices Committee- Metrics Workshop
Measuring Asset Reliability for a Mock Company
Introduction
You will be calculating a set of SMRP Best Practice metrics for a mock company:
“Speedy Mac Reliable Products”
The name of the company shortens to SMRP. The company is based in St. Louis. SMRP has
several plants located in Missouri and Illinois. The company is in the business of manufacturing
reliable widgets for general application.
The company’s CEO, Seymour Profit, envisions starting a reliability initiative, since he has
heard that such efforts can improve the bottom line. He has charged Noah Lott, the Director of
Corporate Reliability, with program implementation.
Noah has extensive experience with the Asset Reliability Process (Figure 1), and decides to
calculate a set of SMRP Best Practice metrics to identify the current state and then determine
some focussed initiatives to propose for implemenation. These metrics are mapped to the process
in Figure 2.
plan
improve
Identify
Business
Goals
Asset Work
Identification
maintenance control
Plan
Schedule
resource control
Requisition
Procure
Asset
Identification
Continuous
Improvement
Loop
Sustained
Maintenance
Loop
Sustained
Resource
Loop
Asset
Prioritization
Asset
Performance
Targets
Asset
Performance
Analysis
Follow-up
Execute
Fulfill
Store
assess
Figure 1. Asset Reliability Process
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Figure 2 SMRP Best Practices Metrics Mapped to the Asset Reliability Process
Mr. Lott forms an Asset Reliability Assessment Team consisting of the Maintenance Manager,
Ben Ignored, the Operations Manager, Maury Ficiency, and the Maintenance Planner, Claire
Voyant from the Louisville facility. Together, they select the appropriate metrics and map them
to the Asset Reliability Process. They then set about calculating the current values. Noah has
collected data from two sister plants as well, which will be used to determine which plant is the
best investment for the program. The data for the three facilities is provided in the following
section.
Your teams assignment is to calculate the specific metrics chosen from the mapped process and
make recommendation on how to improve the facilities. You also recognize that these are
snapshots, and you may have to look at the combination of metrics and make educated guesses
about the state of the plant and utlize that information to assist your initiative selection. You
may also determine that additional metrics must be calculated to identify the real problem.
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Plant Data
Table 1. Data from the Finance Department:
No.
Data
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
RAV
Maintenance Labor Cost
Materials Cost
Overtime Labor Cost
Training Cost
Contractor Costs
Total Maintenance Cost
Stores Inventory Value
Value of Stock Purchased
Capital Improvement Costs
Units
$
Millions
$/year
$/year
$/year
$/year
$/year
$/year
$
$/year
$/year
Plant A
Plant B
Plant C
$293.5
$2,015,634
$2,157,428
$308,428
$125,728
$380,723
$4,987,940
$880,225
$2,640,674
$135,000
$293.5
$7,528,986
$8,058,626
$1,152,069
$325,806
$1,565,935
$18,631,422
$9,389,063
$10,327,970
$504,265
$293.5
$11,204,554
$11,992,759
$1,714,497
$262,087
$2,116,369
$27,290,266
$19,511,647
$9,755,823
$275,000
Units
No.
No.
No.
Hrs/year
Hrs/year
Hrs/year
Plant A
36
2
1
2,880
3,744
7,919
Plant B
134
8
4
7,463
27,970
32,571
Plant C
200
25
4
6,004
83,249
44,021
82,799
311,291
460,021
Table 2. Data From HR:
No.
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Data
Craft Employees
Supervisors
Planners
Training Hours
Overtime Hours
Contractor Hours
Total Maintenance Labor
Hours
Hrs/year
Note: Shaded entries are subtotals
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Table 3. Operations Data
No.
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
Data
Scheduled Downtime
Unscheduled Downtime
Total Downtime
Idle Time
Operating Time
Availability
Average Operating speed
Maximum Achievable speed
Performance Efficiency
Units
Hrs/month
Hrs/month
Hrs/month
Hrs/month
Hrs/month
%
fpm
fpm
%
3-10
3-11
Defect rate
Quality Rate
Plant A
Plant B
Plant C
14
7
21
0
699
97.1%
200
203
98.8%
42
36
78
69
574
79.7%
195
203
96.3%
83
65
148
206
366
50.9%
190
203
93.8%
Dfct/100u
%
2.5
97.5%
9.0
91.0%
15.0
85.0%
Units
Hrs/month
Hrs/month
Hrs/month
Hrs/month
Hrs/month
Hrs/month
Plant A
5,493
969
6,462
1,939
323
5,170
Plant B
15,173
10,115
25,288
2,529
5,058
7,333
Plant C
4,105
36,949
41,054
411
26,685
2,463
Hrs/month
Hrs/month
Hrs/month
Hrs/month
Hrs/month
Hrs/month
$/month
$/month
6,139
2,480
2,456
1,745
1,998
975
$48,638
$18,447
19,977
5,708
3,995
13,706
3,450
2,568
$83,985
$48,586
17,653
4,413
1,765
12,193
1,202
346
$8,422
$6,546
Table 4. Work Management Data
No.
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
Data
Planned Work
Unplanned Work
Total Work
Corrective Work Identified
Reactive Work
Proactive Work (includes
4-11 and 4-12)
Scheduled work completed
PM/PdM Work Planned
PM/PdM Work Completed
Project Work
Predictive Work
Operator Predictive Work
Predictive Work Costs
Operator Predictive Work
Costs
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Table 5. Planner Data
No.
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
Data
Ready to Schedule Backlog
On Hold Backlog
Planned Backlog
Total Backlog
Work Orders in Backlog
Work Orders > 90 days old
Work Orders Processed
Repeat work orders (Rework)
Units
man-days
man-days
man-days
man-days
No.
No.
No./month
No./month
Plant A
617.7
205.8
822.9
1028.6
1006
50
1796
27
Plant B
5378.8
205.8
1536.8
6915.6
6770
677
2694
135
Plant C
11435.3
205.8
1143.5
13722.4
19125
3825
6286
658
Units
No/month
No/month
Plant A
300
6
Plant B
450
22
Plant C
1050
105
Units
$/year
Plant A
$125,000
Plant B
$108,000
Plant C
$52,000
Units
Hrs/shift
Hrs/shift
Hrs/shift
Hrs/shift
Hrs/shift
Hrs/shift
Hrs/shift
Hrs/shift
Plant A
0.50
0.25
0.38
0.50
0.50
0.38
0.25
5.24
Plant B
Plant C
1.75
0.25
0.66
0.88
0.88
0.66
0.25
2.67
Table 6. Storeroom data
No.
6-1
6-2
Data
Transactions
Transactions not filled
Table 7. Cost Improvement Analysis Data
No.
7-1
Data
Training Benefit
Table 8. Work Study Data
No.
8-1
8-2
8-3
8.4
8-5
8-6
8-7
8-8
Data
Travel time
Personal Time
Wait Time
Obtaining Materials
Obtaining Tools
Planning
Administrative
Working
© 2014 SMRP
1.00
0.25
0.56
0.75
0.75
0.56
0.56
3.57
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Best Practices Committee- Metrics Workshop
Table 9. Reliability Study on Pump Group 9
No.
9-1
9-2
9-3
9-4
9-5
9-6
9-7
Data
Number of Pumps
Failures (Repair Event)
Total Repair Time
Work Orders (Maint. Action)
Downtime events
Estimated repair cost
Actual repair cost
9-8
Est.repair hours (Pump 9-3)
9-9
9-10
Actual repair hours (Pump 9-3)
Total Asset Downtime
Units
No.
No/year
Hrs/year
No/year
No/year
$/repair
$/repair
Hrs/repai
r
Hrs/repai
r
hrs/year
Plant A
Plant B
Units
Hrs
Hrs
Days
Weeks
Hrs
Hrs
No.
Plant A
720
8760
365
52
40
8
1
Plant C
52
12
48
24
24
2500
2000
52
24
144
72
60
2500
2600
52
36
288
144
120
2500
3500
6
6
6
4
252
6
936
8
1776
Table 10. Constants
No.
10-1
10-2
10-3
10-4
10-5
10-6
10-7
© 2014 SMRP
Data
Hours in a Month
Hours in a Year
Days per year
Weeks per Year
Hours Available per Work week
Hours per shift
Shifts per Day
Plant B
720
8760
365
52
40
8
1
Plant C
720
8760
365
52
40
8
1
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Best Practices Committee- Metrics Workshop
Acknowledgements
The workshop was developed by the 2006 SMRP Best Practices Conference Track
Subcommittee, whose members were Dick Olver, Jay Padesky, Bob DiStefano, Scotty McLean,
Neil Waugh, Ricky Smith, Jeff Stegemiller, Bruce Hawkins and Jerry Kahn.
The concept for this workshop is based on the “Workshops on Maintenance Indicators”
conducted in Europe by Maintenance Benchmarking Committee of the European Federation of
National Maintenance Societies (EFNMS). Tom Svantesson of the Danish Maintenance Society,
who is the EFNMS committee’s liaison with the SMRP Best Practices Committee, is gratefully
acknowledged for his guidance during the development of this SMRP workshop
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Calculation of the metrics for Breakout Session 1
Please calculate the maintenance Metrics for each SMRP Plant facility
█ Strategic Planning Metrics
Metrics to Calculate: 1.1, 1.5, 2.1.1, and 5.5.71
------------------------------------------------------------------------------------------------------------------------------Metric 1.1 RAV per Craft/Wage Headcount
Replacement Asset Value
Metric 1.1 Formula:
Craft/Wage Headcount
Metric 1.1 Calculation:
Plant A
Plant B
Plant C
Metric 1.1 Result:
______
______
_______
per maintenance employee
------------------------------------------------------------------------------------------------------------------------------Metric 1.5 Maintenance Cost per RAV(Harmonized with EFNMS E1)
Annual Maintenance Cost * 100
Metric 1.5 Formula:
Replacement Asset Value
Metric 1.5 Calculation:
Metric 1.5 Result:
Plant A
______
Plant B
______
Plant C
______ %
------------------------------------------------------------------------------------------------------------------------------Metric 2.1.1 OEE
Metric 2.1.1 Formula:
Availability * Performance Efficiency * Quality Rate
Metric 2.1.1 Calculation:
Metric 2.1.1 Result:
© 2014 SMRP
Plant A
______
Plant B
______
Plant C
______ %
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Best Practices Committee- Metrics Workshop
Metric 5.5.71 Contractor Cost (Harmonized with EFNMS E10)
[Annual Contactor Cost] * 100
Metric 5.5.71 Formula:
Annual Maintenance Cost
Metric 5.5.71 Calculation:
Metric 5.5.71 Result:
Plant A
_____
Plant B
______
Plant C
______ %
Calculation of the metrics for Breakout Session 2
Please calculate the maintenance indicators for each SMRP Plant facility
█ Work Identification Metrics
Metrics to Calculate: 5.3.1, 5.4.1, and 5.1.5
Metric 5.3.1 Planned Work
Planned Work Performed * 100
Metric 5.3.1 Formula:
Total Work Performed
Metric 5.3.12 Calculation:
Metric 5.3.1 Result
Plant A
______
Plant B
______
Plant C
______ %
------------------------------------------------------------------------------------------------------------------------------Metric 5.4.1 Reactive Work (Harmonized with EFNMS O17)
Reactive Work Performed * 100
Metric 5.4.1 Formula:
Total Work Performed
Metric 5.4.1 Calculation:
Plant A
© 2014 SMRP
Plant B
Plant C
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Best Practices Committee- Metrics Workshop
Metric 5.4.1 Result:
______
______
______ %
------------------------------------------------------------------------------------------------------------------------------Metric 5.1.5 Condition Based Maintenance Cost (Harmonized with EFNMS E17)
[Condition Based Maintenance Cost] * 100
Metric 5.1.5 Formula:
Annual Maintenance Cost
Metric 5.1.5 Calculation:
Metric 5.1.5 Result:
Plant A
______
Plant B
______
Plant C
______ %
█ Work Planning Metrics
Metrics to Calculate: 5.4.9
------------------------------------------------------------------------------------------------------------------------------Metric 5.4.9 Ready Backlog (based on a 40 hour workweek)
Ready to Schedule Backlog (weeks)
Metric 5.4.9 Formula:
Craft Available
Metric 5.4.9 Calculation:
Metric 5.4.9 Result:
Plant A
______
Plant B
______
Plant C
_____ weeks
█ Work Scheduling Metrics
Metrics to Calculate: 5.4.3
Metric 5.4.3 Schedule Compliance - Hours
Scheduled Work Performed * 100
Metric 5.4.4 Formula:
Total Time Available
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Metric 5.4.4 Calculation:
Metric 5.4.4 Result:
Plant A
______
Plant B
______
Plant C
______ %
Calculation of the metrics for Breakout Session 3
Please calculate the maintenance indicators for each SMRP Plant facility
█ Materials Control Metrics
Metrics to Calculate: 1.4
Metric 1.4 Stocked MRO Inventory per RAV (Harmonized with EFNMS E7)
Stocked Inventory Value * 100
Metric 1.4 Formula:
Replacement Asset Value
Metric 1.4 Calculation:
Metric 1.4 Result:
Plant A
______
Plant B
______
Plant C
______ %
█ Work Execution Metrics
Metrics to Calculate: 5.6.1
Metric 5.6.1 Wrench Time
Productive Work Time * 100
Metric 5.6.1 Formula:
Total Work Time Scheduled
Metric 5.6.1 Calculation:
© 2014 SMRP
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Best Practices Committee- Metrics Workshop
Plant A
Plant B
Metric 5.6.1 Result:
Plant C
______ %
█ Analysis Metrics
Metrics to calculate: 3.5.1, and 3.5.2
Metric 3.5.1 Mean Time Between Failures (MTBF) for Pump Group No. 9
(Harmonized with EFNMS T17)
Operating Time
Metric 3.5.1 Formula:
Number of Failures
Metric 3.5.1 Calculation:
Metric 3.5.1 Result:
Plant A
______
Plant B
_______
Plant C
______
months
------------------------------------------------------------------------------------------------------------------------------Metric 3.5.2 Mean Time To Repair (MTTR) for Pump Group No. 9
(Harmonized with EFNMS T21)
Repair Time
Metric 3.5.2 Formula:
Number of Repair Events
Metric 3.5.2 Calculation:
Metric 3.5.2 Result:
© 2014 SMRP
Plant A
______
Plant B
______
Plant C
______
hours
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