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





No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Big Data and IIoT value; Monitoring Big Data; Robotics safety standards and programming; Learning about PID
Motor specification guidelines; Understanding multivariable control; Improving a safety instrumented system; 2017 Engineers' Choice Award Winners
Selecting the best controller from several viewpoints; System integrator advice for the IIoT; TSN and real-time Ethernet; Questions to ask when selecting a VFD; Action items for an aging PLC/DCS
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Future of oil and gas projects; Reservoir models; The importance of SCADA to oil and gas
Big Data and bigger solutions; Tablet technologies; SCADA developments
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
click me