Reliability measures the probability that the system will perform without failure over a specified interval under specified conditions. What is Equipment Reliability? Specific metrics for measuring effectiveness in key areas such as maintenance planning and scheduling and MRO storerooms and material management. When objectives are reached, you can remove these measures from the scorecard and add new transition measures. Say the mixer shuts off every hour, while a properly functioning mixer can continuously work for 24 hours without issues. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. Once these short-term indicators are under control, the long-term trends should move in the right direction too. Employees gripe. The goal of a main-tenance and reliability program is to deliver a proper balance of maintenance activities — primarily those aimed at … Insight into behaviors that are encouraged by the use of those metrics. We can refine these definitions by considering the desired performance standards. One of the main KPIs used in this category is called Mean Time Between Failure. How should we respond to changes in the KPI we are measuring? For utility companies, reliability means success. Maintenance metrics matter. The financial impact of unexpected equipment failure can be costly, as AK Steel Corp. shared recently. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). 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. Adequate Level of Reliability (ALR) Metrics. Box 460Yulee, FL 32041-0460Call us: 1-843-814-3795. 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. Achieved Availability 6. All of these factors can be immediately actioned in order to resolve the problem. There are loads of metrics that are relevant and important to utilities, but three, in particular, are crucial for tracking reliability success. 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. This could be due to things like breakdowns in equipment or a lack of availability of spares to execute the planned work. Below are some practical steps to help facilitate a discussion on the right KPIs and approach for your organization. Data Quality. Asset performance metrics like MTTR, MTBF, and MTTF are essential for any organization with equipment-reliant operations. Reliability may be Reliability = V x 100 W The frequency with which the machine breaks down and disrupts production Data 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. 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. Reliability must be sufficient to support the warfighting capability needed in its expected operating environment. Taxonomy Definitions. 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. 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. 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. 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. 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. Average Uptime Availability (or Mean Availability) 3. Sometimes this global goal is expressed in terms … Steady State Availability 4. Interested in breaking information silos, standalone solution, and inconsistent processes in your organization? It is the big picture that all of our own individual contributions and department goals are helping to achieve. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. You can try us out by signing up today for a free 15-day trial. Overall Equipment Effectiveness (OEE). 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. So, which metrics should utility executives care about? Reliability Consultant, Ivara Ron Thomas Director of Reliability Practices, Dofasco ... relate to manufacturing metrics. Can we control both long-term trends and short-term changes in culture and behavior? 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. 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. 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. Considerations of reliability must support both availability metrics. Reliability is the probability that a system performs correctly during a specific time duration. People and Processes, Inc.P.O. "The No. 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. MPU is a simple ratio which can be measured against benchmarks for each specific industry. 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. 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. Establishing metrics is essential for demonstrating the benefits of maintenance and reliability best practices. Without them, you wouldn’t know how you were doing, much less how you can improve. 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. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. 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. The original metric, Mission Reliability, answered the question of figure 4. 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. You know maintenance needs better software and you’ve found the perfect solution. Planned maintenance percentage (PPC) This metrics represents the percentage of time spent on … These goals are determined by the individual organization. People often confuse reliability and availability. Check out our handy guide for clearing the last hurdle: executive buy-in. PSA can be calculated as a percentage and should be as close to 100% as possible. Inventory Turns. Technicians can extend the equipment’s availability by increasing its reliability. The Society for Maintenance and Reliability Professionals (SMRP), developed standard definitions for metrics used in industry. Another major trend indicator is the financial KPI of Maintenance Cost per unit Production. Learn how digital permitting can reduce hazardous incidents, mitigate unsafe isolations and sub-par risk assessments, and ensure regulatory compliance. While the availability of the faulty mixer may still be quite high if opera… The three basic metrics of RAM are (not surprisingly) Reliability, Maintainability, and Availability. EZOfficeInventory is the leading equipment management software used by companies worldwide. Author, Ron Moore, suggests that process conformance can be improved through equipment reliability, proper, calibrated instrumentation, disciplined operation and quality raw material1. MTTR, also referred to as maintainability measures the ability to do maintenance to keep or restore equipment to a specified operating condition. When measuring reliability, consideration must be given to the data contained in management reports. Which ones do we focus on and why? 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. 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. dated equipment with the latest technology. Using the wrong maintenance metrics—or worse yet none at all—can cause or contribute to problems like the following. 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. Tracking the reliability of assets is one challenge that engineering and maintenance managers face daily. 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. Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. However, new technology only enables an ineffective maintenance program to be more efficient at being ineffective. Investigations into the causes of failures can help prevent breakdowns. As a hypothetical example, imagine a faulty mechanical mixer. 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). 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. As a result, there are a number of different classifications of availability, including: 1. It is calculated by dividing a specified period of operating hours by the number of failures. These KPIs help us to determine if all the little day to day adjustments and changes are actually having the desired effect over time. There are literally hundreds of KPIs published that we are told should help us to measure and control our manufacturing, reliability and maintenance performance. 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. A simple measure for this is Production Schedule Adherence, which can be measured as: PSA = Actual Production / Planned Production. 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. It encompasses availability, performance, and quality, and when used correctly is removing waste. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. Equipment Metrics and Benchmarking 5 5 1. However, the result of this change may only be noticeable in the reduction of failures over a period of weeks and months. And, how can project managers ensure their teams accomplish those reliability goals? 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. 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