By: Amit | 13 Mar 2006 1:36 am | 5260 times viewed | 2 Comments
I want to prepare a set of Plant Maintenance Key Performance Measures.
Can anyone share if they have done anything similar? What are the most appropriate Plant Maintenance Performance Measures and how are these obtained/calculated?
Also, what platform are these KPIs displayed in ? eg Business Warehouse, Cognos ?
During myprevious implementation there were THREE KPI`s were decided for the client in integration with BIW.
1) Breakdown time reduction using effective pM schedulling of equipments and
2) Improving productivity by reducing down time.
3) Machine relaibility index
All three were achived using PM Notification,PP order confirmation and using breakdown duration of M2 type notfication.
It seems we are also trying to achieve similar objectives to what you stated - that is to reduce Breakdown Maintenance by better Predictive Maintenance. Thereby reducing downtime and improve reliability.
Do you recall how you calculated the:
1) reduction in breakdown time ?
2) Were your people deligent about using the Breakdown Indicator and durations in the Notification ?
Did you extract this to BW or use it in R/3 ? How did you present the KPIs ?
Calculating reduction in break down time:
You need to understand where the data to calculate this comes from.
1. The valid from date in the equipment master or functional location needs to be populated. This gives the start date for mean time to failure calulation. If this is not populated then SAP starts the calculation from the date of the first notification raised for the equipment.
2. The breakdown box must be ticked
3. the breakdown start and end dates and times must be entered, the system will calculate the duration
The valid from date starts the clock. When a breakdown is recorded, the time between the start and end dates and times give the Time To Repair. When there is more than one break down, this gives the Mean Time To Repair.
The Mean Time to Failure is calculated from the average of the times between the failures.
Transactions for these reports are
1. MCJB - MTTR/MTBR Equipment
2. MCJC - MTTR/MTBR Functional Location
They are quite good reports
You ask about the diligence of the people populating the system.
To achieve this, you need well defined and documented business processes.
you need to train your people in doing this and also WHY they need to do this and WHY they need to be accurate with the data entry.
This training needs to be a part of their SAP training, so that you are providing process based SAP training rather than transaction based training.
The people entering this data should be maintenance people and they need to know who looks at it and what it's used for. If they think no one uses the data, they're less likely to enter it
To underwrite these points, you need business discipline which is understood and supported by all levels of management
How to present thes KPIs.
Can be as simple as story boards in the process plant which are updated daily. Everyone can see the progress. This is a great way to get the story across if you include production KPIs as well such as level of production achieved and $$ generated for the business. People then see a direct correlation of increased breakdowns = increased costs = reduced income.
It may be dumped into Excel and e-mailed to those who need the info
It may be extracted using BW and displayed in the intranet.
It may be a story in your company's news letter on a regular basis, but what ever you do, you need to raise the awareness at all levels, from the cleaner to the site manager. They are all a part of your predictive maintenance team.