Composite maintenance benchmark metrics

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.
By Richard L. Dunn January 1, 1999

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