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.

01/01/1999


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





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