Representative Representative
GENERAL COST RATIOS best practice range
Mtce cost/ERV
Process 2.3% 2% - 5%
Discrete 2.0% 2.0% - 5.0%
Total mtce cost/total sales
Process 3.4% 1.5% - 5%
Discrete 0.9% 0.6% - 2.2%
Mtce labor cost/total sales
Process 1.5% 0.6% - 2.1%
Discrete 0.5% 0.4% - 1.1%
Mtce materials cost/total sales
Process 1.9% 0.8% - 2.4%
Discrete 0.4% 0.2% - 1.1%
ERV ($millions)/technician $7.5 $3.2 - $7.5
ERV ($millions)/mtce and reliab. engineer -- $55 - $250
MAINTENANCE PERFORMANCE
Work order coverage
Process 100% 80% - 95%
Discrete 100% 80% - 95%
Schedule compliance (overall) >70% 35% - 70%
Preventive maintenance
Process 95% 80% - 100%
Discrete 95% 65% - 95%
Planned repairs
Process 95% 70% - 95%
Discrete 90% 65% - 80%
Planned work (overall) 95% 65% - 95%
Overall equipment effectiveness >78% 48% - 78%
Uptime >90% --
Availability
Discrete 91% 78% - 91%
Process >95% 85% - 95%
PM+PdM by operators 25% 10% - 25%
Mtce labor cost/total mtce cost -- 20% - 45%
Contractor cost/total mtce cost -- 10% - 40%
LABOR/HUMAN RESOURCES
OSHA injuries/200,000 hr <1 --
Technicians/supervisor -- 15 - 25
Technicians/support person 5 2 - 8
Technicians/planner 30 - 40 20 - 80
Technicians/total workforce -- 10% - 30%
Maintenance craft classifications 2 2 - 7
PM+PdM manhours/total mtce manhours 40% 18% - 40%
Emergency manhours/total mtce manhours
Process 2% 2% - 20%
Discrete 5% 5% - 30%
"Wrench time"/Total mtce manhours 52% 30% - 50%
Representative Representative
MATERIALS MANAGEMENT best practice range
Stores value/ERV 1% - 2% 0.3% - 2.3%
Stores turnover 1.4 0.3 - 1.2
Stores inventory accuracy 99% 85% - 99%
Stores disbursements/stores personnel $600,000 $350,000 - $600,000
Sources: Fluor Daniel, NAME Awards, McGladrey & Pullen/National Association
