Planned versus Unplanned Work
What exactly should be measured is for the user to decide, and will be the source of much discussion. Requirements will also depend on whether the situation is viewed from an engineering or an accounting perspective. What is important on one site may be of no consequence on another. However, one of the universal objectives of any maintenance improvement plan must be to improve the ratio of planned versus unplanned work. Clearly, the ultimate aim must be to move the unplanned maintenance level as far as possible toward zero. In practise many unorganised maintenance departments will have a ratio of 90% unplanned to 10% planned work; much of their work will be reactive. A CMMS will make this easy to monitor and produce a suitable metric. Over a period it can be used, along with the other statistics which will be available, to reverse the trend.
Just a few of the many other maintenance metrics, which may be relevant, are listed below:
Man hours unallocated (unproductive hours)
% Overtime hours
Cost of maintenance overtime
Backlog of work
Average time per breakdown job
Cost of spares
Cost of labour
Equipment effectiveness
Total maintenance cost per unit of output
Cost of lost output due to unplanned downtime
Cost of lost output due to planned downtime
Downtime percentages, by area and by asset
Mean Time Between Stops or Mean Time Between Failures
Any investment in CMMS will be dependent on the size of the system required. In a small company a single user system on a stand-alone PC may suffice. The hardware and software cost for this could be less than ฃ2K. In a large company where all available options are required on a 40-user system the costs could be ฃ200K. The amount of personnel required to implement the system will again be dependent on the size of the system but on a large multi-user system one to two man-years would not be unusual. On-going costs of system administration and support must be considered along with any software support contracts, which are involved. There is no magic wand, which can be used to implement CMMS. No matter what your approach it is likely to require considerable investment, in terms of finance and manpower.
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Planned versus Unplanned Work
What exactly should be measured is for the user to decide, and will be the source of much discussion. Requirements will also depend on whether the situation is viewed from an engineering or an accounting perspective. What is important on one site may be of no consequence on another. However, one of the universal objectives of any maintenance improvement plan must be to improve the ratio of planned versus unplanned work. Clearly, the ultimate aim must be to move the unplanned maintenance level as far as possible toward zero. In practise many unorganised maintenance departments will have a ratio of 90% unplanned to 10% planned work; much of their work will be reactive. A CMMS will make this easy to monitor and produce a suitable metric. Over a period it can be used, along with the other statistics which will be available, to reverse the trend.
Just a few of the many other maintenance metrics, which may be relevant, are listed below:
Man hours unallocated (unproductive hours)
% Overtime hours
Cost of maintenance overtime
Backlog of work
Average time per breakdown job
Cost of spares
Cost of labour
Equipment effectiveness
Total maintenance cost per unit of output
Cost of lost output due to unplanned downtime
Cost of lost output due to planned downtime
Downtime percentages, by area and by asset
Mean Time Between Stops or Mean Time Between Failures
Any investment in CMMS will be dependent on the size of the system required. In a small company a single user system on a stand-alone PC may suffice. The hardware and software cost for this could be less than ฃ2K. In a large company where all available options are required on a 40-user system the costs could be ฃ200K. The amount of personnel required to implement the system will again be dependent on the size of the system but on a large multi-user system one to two man-years would not be unusual. On-going costs of system administration and support must be considered along with any software support contracts, which are involved. There is no magic wand, which can be used to implement CMMS. No matter what your approach it is likely to require considerable investment, in terms of finance and manpower.
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