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  • 1.  Maintenance Workload by activity best in class

    Posted 07-07-2022 01:05 PM
    Hello everyone,

    I hope all of you are enjoying the good weather..;)

    I am looking for any feedback about Best Practices and/or an Average Maintenance workload  percentage  distribution. Let's have as an example the following information as an average from first to fourth quartile, the following example would be placed on the second or third quartile ( I am estimating for the sake of this example)

    1- Break in (urgent)  10%
    2- Corrective deferred  10%
    3- Routine Work (PM routines) 55%
    4- Workload as a result of findings and actions coming from Routine Work 15%
    5- Plant support and Plant Improvements 10% 

    This totalize 100% of the Maintenance workload.

    Your feedback would be as always appreciated

    Best Regards

    Rene M. Davila


  • 2.  RE: Maintenance Workload by activity best in class

    Posted 07-08-2022 10:16 AM
    The worst thing I could do as a competitive runner is to start my race at the pace of the racers around me if I have not trained with them and know their physiological characteristics. As a result I could loose the race at their pace or worse fail to finish.

    Rather than "best practice" is the "ideal practice" of forming a workload based maintenance budget for the plant and use it as my baseline by extracting the plant-specific statistics you ask about. I could also use the extractions to set a target for shifts in the categories--assuming there is something upon which the assumed shifts will ocur. 

    Additionally, ideal practice would be to extract the categorical statistics by maintenance events and labor hours. Of course for the latter you had better be sure your time sheets are accurate. Some plants tend to place all hours on less than all of the orders resulting in misinformation in the one data that is most significant to achieving cost effective maintenance..






  • 3.  RE: Maintenance Workload by activity best in class

    Posted 07-08-2022 11:33 PM
    Hello Richard,

    As always, thanks for your feedback.

    Best Regards

    Rene Davila



    Original Message


  • 4.  RE: Maintenance Workload by activity best in class

    Posted 07-08-2022 07:48 PM
    Rene,

    Being a member of SMRP provides free access to the Best Practices Metrics including the Best Practice Compendium, 6th Edition. In the Compendium, Guideline 5.0, Maintenance Work Types, defines various types of maintenance work.

    The following Metrics will help you measure the percentage of total maintenance work for specific work types:

    5.4.1 Reactive Work
    5.4.2 Proactive Work
    5.4.12 Preventative Maintenance (PM) & Predictive Maintenance (PdM) Yield
    5.1.13 Preventative Maintenance (PM) & Predictive Maintenance (PdM) Effectiveness
    5.7.1 Continuous Improvement Hours

    If you are looking at workload, Metrics focused on Planned Work and Backlog may provide value:

    5.3.1 Planned Work
    5.4.8 Planned Backlog
    5.4.9 Ready Backlog

    Many of these metrics have Target Values for best in class performance as well as a flowchart showing the recommended percentage of work.

    Due to the many different industry structures, the Best Practices Committee has not developed or published benchmark targets for first to fourth quartile performance, focusing instead on Best-in-class performance.

    Best Regards,

    Michael Raible, Chair Best Practices Committee




  • 5.  RE: Maintenance Workload by activity best in class

    Posted 07-08-2022 11:29 PM
    Hello Michael,

    Thanks, I thought I saw something in the past but I was not sure. I will take a look.

    Best Regards

    Rene Davila



    Original Message


  • 6.  RE: Maintenance Workload by activity best in class

    Posted 07-11-2022 07:55 AM
    Once upon a time best practice metrics were called "benchmarks." The idea of gathering benchmarks emerged in the 1990s as the exciting idea of the month. The problem with best practice metrics is that we don't know much about their context and whether they fit our cases or could actually be destructive to us. Furthermore, if best practices metrics were as insightful as we always want to believe they are, we would possibly be taken to court for industrial spying.

    It is necessary to develop metrics for our own cases. Unfortunately, in the last several decades there has been a buyin to the idea that we know longer need to work hard to figure out how to make our operations effective and efficient.

    At best, best practice metrics are valuable as candidate constructs to consider for our case. However, when we solve our own cases we should discover unique constructs linked to our aspirations for the operation.



    Original Message


  • 7.  RE: Maintenance Workload by activity best in class

    Posted 07-25-2022 08:29 PM
    Hi Rene,
    Data integrity was the challenge when we recently worked on determining our historical percentages for workload. If the data shows a low technician utilization rate but observation indicates otherwise, there is some research and educated guessing needed to fill in the blanks and a lot of coaching to techs on the importance of an accurate and complete historical record.  

    Not to avoid the question, but I don't know I've found it particularly useful to think of the workload breakdown as independent buckets with targets.  PM effectiveness (comparing your 3 to 1,2 and 4) has proven insightful.  Also might be helpful to think of 5 as two categories: the support being techs engaged with operators (training, addressing minor issues, etc) and the improvements being separate line improvements but not necessarily interactions with operators.

    Regards,
    Anthony

    ------------------------------
    Anthony Scaletti
    Maintenance Manager
    Nestle Purina
    Allentown PA
    ------------------------------



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