|
Best Practices Maintenance Benchmarks |
|
Category |
Benchmark |
| Yearly
Maintenance Cost: |
|
|
Total Maintenance Cost/Total Manufacturing Cost |
< 10-15% |
|
Maintenance Cost/Replacement Asset Value of the Plant and Equipment |
< 3% |
| Hourly
Maintenance Workers as a % of Total |
15% |
| Planned
Maintenance: |
|
|
Planned Maintenance/Total Maintenance |
> 85% |
|
Planned & Scheduled Maintenance as a % of hours worked |
~85-95% |
|
Unplanned Down Time |
~0% |
|
Reactive Maintenance |
< 15% |
| Run to
Fail (Emergency + Non-Emergency) |
< 10% |
|
Maintenance Overtime: |
|
|
Maintenance Overtime/Total Company Overtime |
< 5% |
| Monthly
Maintenance Rework: |
|
|
Work Orders Reworked/Total Work Orders |
~0% |
|
Inventory Turns: |
|
|
Turns Ration of Spare Parts |
> 2-3 |
|
Training: |
|
|
For at least 90% of workers, hours/year |
> 80 hours/year |
|
Spending on Worker Training (% of payroll) |
~4% |
| Safety
Performance: |
|
|
OSHA Recordable Injuries per 200,000 labor hours |
< 2 |
|
Housekeeping |
~96% |
| Monthly
Maintenance Strategies: |
|
| Preventive
Maintenance: Total Hours PM/Total Maintenance Hours Available |
~20% |
| Predictive
Maintenance: Total Hours PdM/Total Maintenance Hours Available |
~50% |
| Planned
Reactive Maintenance: Total Hours PRM/Total Maintenance Hours
Available |
~20% |
| Reactive
Emergency: Total REM/Total Maintenance Hours Available |
~2% |
| Reactive
Non-Emergency: Total RNEM/Total Maintenance Hours Available |
~8% |
| Plant
Availability: |
|
|
Available Time/ Maximum Available Time |
> 97% |
|
Contractors: |
|
|
Contractors Cost/Total Maintenance Cost |
35-64% |
