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.
System integration: Best practices and technologies to help; Virtualization virtues; Cyber security advice; Motor system efficiency, savings; Product exclusives; Road to Hannover
Collaborative robotics: How to improve safety, return on investment; Industrial Internet of Things, Industrie 4.0: World views; High-performance HMI, Information Integration: OPC and OMG
9 tips: How to integrate a servo system; Process control mathematical models; Serial network grounding; Engineers' Choice Awards; Learn from cyber security mistakes
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
PLCs, robots, and the quest for a single controller; how OEE is key to automation solutions.
This article collection contains several articles on improving the use of PID.
Learn how Industry 4.0 adds supply chain efficiency, optimizes pricing, improves quality, and more.

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

Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
click me