5 industrial maintenance KPIs to increase your efficiency
As a manager of quarry, the continuity of your production line is a major issue. Maintenance is a powerful lever: the faster and more efficiently you intervene, the faster the incident can be closed.
In this article, we share the 5 KPIs of industrial maintenance that are essential to know in order to analyze the performance of a maintenance department, a technical team or a technician, with regard to the capacity to react in the treatment and management of anomalies that may occur in the technical resources.
1. Evaluate the reliability of equipment
The MTBF or Main Time Between Failure indicator is used here. In other words, it measures the time interval between failures of your machines.
The calculation is as follows: total operating time / number of failures
For example, if over 3 months, your machine has been working for 225 hours and has accumulated 10 breakdowns, this represents 20 hours of breakdowns.
We take the time on which the machine has actually worked: 225-20 = 205
We divide this time by the number of failures: 205/10 = 20.5
This indicator will allow you to:
- to anticipate the breakdowns of your machines
- determine if your machine is obsolete and if you need to invest in a new one.
You can also complete it with the failure rate.
The calculation is as follows: number of failures / total operating time x 100
If we take our example: 10/225x100 = 4.4%.
2. Measuring the effectiveness of interventions
We use the indicator MTTR or Main Time to Repair. In other words, you measure the average time spent on a maintenance intervention.
The calculation is as follows: sum of the time of maintenance operations / number of maintenance operations
For example, if your team conducted 5 interventions that lasted 2 hours each:
We calculate the total maintenance time: 2x5 = 10
Then we calculate the repair rate: 10/5 = 2
This indicator will allow you to :
- measure the efficiency of your maintenance operations
- control the maintainability of the equipment
3. Estimate the ability to respond to an incident
Here, different indicators can be used, all based on elapsed time.
Between the incident and its detection
It is possible to be quickly informed thanks to the insertion of sensor networks that generate alerts by e-mail, SMS or on your management software.
Between detection and release of the work order
To minimize this time, you can create order templates or use digital tools to communicate more quickly.
Between the work order and the beginning of the intervention
The processes must be clarified upstream to facilitate a seamless response.
Between the beginning of the intervention and the diagnosis
The skills of the technician are important, but not the only factors. The quality of the technical documentation, the ease of access to the machine, the customer support of your supplier, are also elements to take into account.
If the quarry is well equipped, the technician can retrieve on his phone the history of incidents, the reports, the search strategy, from a common technical database.
4. Determine the performance of your equipment
The synthetic rate of return is used here. In other words, it is used to evaluate the difference between the theoretical production of a piece of equipment and its actual production.
The calculation is as follows: operation x performance x quality
Here's how to calculate the intermediate variables:
- the operating rate : gross time / theoretical time x 100
- the performance rate : net time / gross time x 100
- Quality rate : useful time / net time x 100
Theoretical or total time: the machine works 100% of the time
- minus the closing hours of quarry = opening time
- minus planned downtime (scheduled maintenance...) = time required
- minus breakdowns = gross time
- minus microstops (breaks, cleaning...) = net time
- minus the time spent producing scrap or reworking non-quality production = useful time
For example, if the theoretical time is 100 hours, the gross time is 80 hours, the net time is 70 hours and the useful time is 50 hours:
- the operating rate: 80/100x100 = 80%.
- the performance rate: 70/80x100 = 87.5
- the quality rate: useful time / time: 50/70x100 = 71.4%.
This indicator is particularly dependent on the calendar, in particular public holidays and vacations, changes in demand and therefore production, stock-outs, etc...
5. Calculate maintenance costs
This indicator is in fact a sum of costs:
- direct costs, such as spare parts, but also internal or subcontracted labor
- Indirect costs, such as production downtime
This amount then allows you to estimate the ROI of acquiring a new machine compared to the cost of your current machine.
In conclusion, industrial maintenance indicators are used to analyze results and make optimized decisions. They are essential to improve loading, communication, travel or waiting times on a site.
To set up tracking KPIs quickly and easily, we recommend using a digital solution. Our teams are available to discuss your needs and action plan with you. To get in touch with us free of charge, click here!
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