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. You know maintenance needs better software and you’ve found the perfect solution. Insight into behaviors that are encouraged by the use of those metrics. © 2020 Prometheus Group All Rights Reserved. It is vital that each function and department links themselves to the overarching objective of the whole. 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. 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. Can we control both long-term trends and short-term changes in culture and behavior? Technicians can extend the equipment’s availability by increasing its reliability. 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. Below are some practical steps to help facilitate a discussion on the right KPIs and approach for your organization. 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. 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. 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. Maintenance and reliability managers must have metrics in place to identify needs for improvement. Reliability = V x 100 W The frequency with which the machine breaks down and disrupts production Data 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. "The No. Request a Demo of the Prometheus Platform. Interested in breaking information silos, standalone solution, and inconsistent processes in your organization? As a hypothetical example, imagine a faulty mechanical mixer. Data Quality. It identifies the percentage of manufacturing time that is truly productive. Taxonomy Definitions. Sometimes this global goal is expressed in terms of profitability, sometimes in terms of revenue, sometimes in terms of production. Achieved Availability 6. 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. There are many KPIs that enable us to monitor the long-term trends in reliability and maintenance performance. Reviews of the bill of materials for maintenance tasks can improve the planning data. Requirements for a Successful Reliability Team. Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. When objectives are reached, you can remove these measures from the scorecard and add new transition measures. Corporate Metrics. It's necessary to change their opinion by changing your perspective. Author, Ron Moore, suggests that process conformance can be improved through equipment reliability, proper, calibrated instrumentation, disciplined operation and quality raw material1. The value of having a global KPI like this in every department is that it reminds everyone of the collective responsibility for overall performance. Another metric that relates to the duration that an equipment operates is reliability. However, new technology only enables an ineffective maintenance program to be more efficient at being ineffective. Overall Equipment Effectiveness (OEE). Employees gripe. Using the wrong maintenance metrics—or worse yet none at all—can cause or contribute to problems like the following. 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. 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. Reliability can be characterized in terms of the parameters, mean, or any percentile of a reliability distribution. 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. MTBF is the average length of operating time between failures for a specific piece of equipment or component. dated equipment with the latest technology. Reliability may be 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. Inventory Turns. The Society for Maintenance and Reliability Professionals (SMRP), developed standard definitions for metrics used in industry. 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. Steady State Availability 4. 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. 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. The financial impact of unexpected equipment failure can be costly, as AK Steel Corp. shared recently. PSA can be calculated as a percentage and should be as close to 100% as possible. Reliability uses many metrics for evaluating equipment and systems. 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. 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. Learn how digital permitting can reduce hazardous incidents, mitigate unsafe isolations and sub-par risk assessments, and ensure regulatory compliance. The three basic metrics of RAM are (not surprisingly) Reliability, Maintainability, and Availability. For industrial maintenance, the metric of Failure Rate is usually more relevant. Equipment fails. 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. 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. 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. A simple measure for this is Production Schedule Adherence, which can be measured as: PSA = Actual Production / Planned Production. Establishing metrics is essential for demonstrating the benefits of maintenance and reliability best practices. Measuring plant performance - The need for metrics standardization. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. 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). 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. There are loads of metrics that are relevant and important to utilities, but three, in particular, are crucial for tracking reliability success. How should we respond to changes in the KPI we are measuring? 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. PMSC can also be calculated as a percentage and should be as close to 100% as possible. Equipment Metrics and Benchmarking 5 5 1. It is calculated by dividing a specified period of operating hours by the number of failures. Reliability metrics are best stated as probability statements that are measurable by test or analysis during the product development time frame. One of the main KPIs used in this category is called Mean Time Between Failure. Here you can focus on three main areas for which you can define additional KPIs: assets, operational and customers. You can try us out by signing up today for a free 15-day trial. Equipment Metrics and Benchmarking 5 5 1. Specific metrics for measuring effectiveness in key areas such as maintenance planning and scheduling and MRO storerooms and material management. Sometimes this global goal is expressed in terms … And, how can project managers ensure their teams accomplish those reliability goals? Say the mixer shuts off every hour, while a properly functioning mixer can continuously work for 24 hours without issues. Inherent Availability 5. Warnings of pitfalls to avoid as part of the metrics process. 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. When measuring reliability, consideration must be given to the data contained in management reports. Asset performance metrics like MTTR, MTBF, and MTTF are essential for any organization with equipment-reliant operations. 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. Once these short-term indicators are under control, the long-term trends should move in the right direction too. MPU = dollars spent on maintenance / production achieved. Instantaneous (or Point) Availability 2. EZOfficeInventory is the leading equipment management software used by companies worldwide. Use data-driven decision-making for equipment assets to optimize profitability, safety and compliance. 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. Reliability must be sufficient to support the warfighting capability needed in its expected operating environment. The goal of a main-tenance and reliability program is to deliver a proper balance of maintenance activities — primarily those aimed at … Convincing your executive team to purchase new software can be a challenge. Reliability measures the probability that the system will perform without failure over a specified interval under specified conditions. These KPIs help us to determine if all the little day to day adjustments and changes are actually having the desired effect over time. This could be due to things like breakdowns in equipment or a lack of availability of spares to execute the planned work. 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. All of these factors can be immediately actioned in order to resolve the problem. Before diving into the reliability program key elements, we must understand the meaning of equipment reliability. What is Equipment Reliability? 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. The purpose of most equipment in manufacturing is to support the production of People often confuse reliability and availability. 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