8 Important Maintenance Metrics to Benchmark for KPIs
While people often use maintenance metrics and key performance indicators (KPIs) interchangeably, there are some differences between the two. Maintenance metrics measure how your team is performing toward specific business activities, whereas KPIs measure progress toward key business objectives. The former is relevant only for specific departments and can vary from team to team, but the latter stays the same across all departments, as KPIs help track large-scale goals.
Achieving long-term success is difficult if you don’t use the right parameters to track performance. Because, in that case, you would not be able to identify your team’s strengths and weaknesses, strategically allocate resources, and modify processes to ensure maximum productivity. To create an effective strategy using data-driven performance indicators, you will have to combine several important maintenance metrics.
In this helpful guide, we will look at eight metrics and outline how to calculate them, as well as why they are essential for measuring your team’s progress.
Overall Equipment Effectiveness (OEE)
OEE helps you assess productivity by combining three factors: availability, performance, and quality. It provides a comprehensive view of how well your equipment is performing.
How to Calculate: Availability × Performance × Quality
- Availability = Actual operating time / Planned production time
- Performance = Actual production rate / Ideal production rate
- Quality = Good units produced / Total units produced
What Does It Mean: An OEE score of 85% and higher is considered ideal for manufacturers, a score between 60-85% has some room for improvement, and a score lower than 60% suggests considerable inefficiencies
Mean Time Between Failures (MTBF)
MTBF is the average time a piece of equipment functions before encountering a failure. This metric helps predict asset reliability and maintenance needs.
How to Calculate: Total operating time of an equipment / Number of failures
What Does It Mean: Higher MTBF refers to better reliability; the benchmark for MTBF varies from 500 to 2,000 hours depending on the industry, type of equipment, and its use cases
Mean Time to Failure (MTTF)
MTTF indicates the average time an asset functions before it fails beyond repair. This metric is particularly useful for monitoring non-repairable equipment.
MTTF differs from MTBF in that it calculates the time taken before irreparable failure, whereas MTBF measures the time between reparable failures.
How to Calculate: Total operating time / Number of failed assets
What Does It Mean: Higher MTTF for an asset indicates it has a longer lifespan; benchmarks vary anywhere between 1,000 and 5,000 operating hours across industries
Mean Time to Repair (MTTR)
MTTR calculates the average time taken to repair a piece of equipment after a failure and return it to operational status. This metric directly affects production capacity and equipment availability in industrial facilities.
How to Calculate: Total repair time / Number of repairs
What Does It Mean: Lower MTTR indicates quicker repair times and higher maintenance efficiency
Schedule Compliance
This metric helps you assess how effectively your team adheres to the maintenance schedule. In other words, it tracks the percentage of maintenance tasks that are completed on time.
How to Calculate: (Completed scheduled tasks / Total scheduled tasks) × 100
What Does It Mean: The benchmark for schedule compliance is 90% or higher, which indicates your team has completed most of their tasks on time
Equipment Downtime
This parameter monitors the percentage of time equipment is out of service due to repairs, failures, or maintenance. It helps keep track of operational efficiency and assess the reliability of certain assets.
How to Calculate: (Total downtime hours / Total operating hours) × 100
What Does It Mean: A score of 5% or lower is ideal; a higher score might suggest that some of your equipment has aged to the point of needing frequent repairs
Remaining Asset Value (RAV)
RAV compares the current value of an asset to its original purchase price. It helps you determine whether it is more cost-efficient to repair or replace an asset.
How to Calculate: (Current asset value / Original purchase value) x 100
What Does It Mean: An RAV of 50% or lower suggests that an asset is nearing the end of its operational period
Work Order Completion Rate
This metric helps track the percentage of work orders completed within a set time period and provides insights into how well your team has been meeting maintenance objectives.
How to Calculate: (Completed work orders / Total work orders) × 100
What Does It Mean: A score of 90% or higher means your team is excelling; if the score falls below 85%, it might be time to review how your team has been prioritizing their tasks
Conclusion
Maintenance KPIs provide valuable insights into your team’s maintenance operations. Over time, they help you identify areas for improvement and eliminate inefficient processes. Tracking KPIs also helps your team meet its goals and work towards long-term, sustainable success.