10 key indicators of maintenance performance
- Mechanical availability (asset utilization) The "business contribution" of maintaining personnel is to provide highly reliable equipment at the lowest possible cost.
- Mechanical availability (asset utilization)
The "business contribution" of maintaining personnel is to provide highly reliable equipment at the lowest possible cost. World-class plants are typically driving reliability rather than cost reduction. (Industry sensitive)
- Ratio of direct maintenance personnel to support maintenance personnel
World-class plants tend to fall in the range of 2:1 to 3:1 workers per support person. Support personnel are those who provide the supervision, parts management, planning, reliability improvement, equipment condition monitoring, and other supporting tasks for the "hands on" workers.
- Ratio of direct maintenance personnel to maintenance planning personnel
- Ratio of direct maintenance personnel to engineering and technical maintenance personnel
There is usually a correlation between this metric and a plant's equipment reliability and costs.
- Maintenance cost as a percentage of plant estimated replacement value
This value is a classic measure of maintenance cost. Unfortunately, by itself, it drives cost reduction behavior without necessarily reinforcing the need for improved maintenance practices.
- Ratio of plant estimated replacement value (in millions) to direct maintenance workers
This value is a measure of direct maintenance worker productivity ("How much plant and equipment,
in dollars, can each worker maintain?"). Many world-class plants fall into the range of $6-$9 million/worker. (Somewhat industry sensitive)
- Maintenance contracting cost as a percentage of total maintenance cost
This value is a measure for comparison, but without a "target" value. World-class plants don't shoot for a specific level; rather, they are disciplined in defining the role of contractors in maintenance, based
on business-related criteria. On average, top plants around the world contract over 30% of their maintenance work -- a little less in the United States. But, top plants are driven by a defined
strategy, not a target percentage.
- Stores parts and investment as a percentage of plant estimated replacement value
For years, the target for this measure was about 1%, but top plants around the world now routinely achieve ratios in the range of 0.25%-0.5%
- Stores turnover (ratio of annual disbursements to inventory value)
This ratio reflects stocking strategy and may run above or below 1 depending on the plant's strategy (for example, balancing risk against insurance stocks). Performance is measured against the plant's own target.
- Ratio of stores disbursements to stores personnel (dollar investment/stores person)
This value is a measure of "productivity" of the stores operation and associated personnel.
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Annual Salary Survey
Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.
There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.
But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.
Read more: 2015 Salary Survey