How to Efficiently Set Up Preventive Maintenance (PM) Compliance, Percentage of PM and Critical Percentage of PM?
Preventive maintenance is the solid base of every successful maintenance strategy and therefore one of the most important components in the management of your maintenance department. Before deploying sensors, condition-monitoring techniques and daring to go further, every organization should ensure the establishment of preventive maintenance routines. The good planning of these ones will allow maintenance professionals to reduce equipment downtime and improve the reliability of the company’s machine park.
The adoption of an efficient preventive maintenance program goes hand in hand with the deployment of a next-gen CMMS. The main goal of a computerized maintenance management system is to correspond to the expectations of the field and provide a user-friendly solution with a mobile app. This feature is of critical importance to all field operators, allowing them real-time information exchange. Mobility Work is an elaborated SaaS CMMS, especially designed to ease the daily routines of the maintenance team through newsfeed, geolocation tool, search engine, analytics tool, and many more.
Mobility Work can help you determine what data is of greater importance for your organization, and by analyzing it, to deliver powerful insights into your assets health. The 3 following indicators will help you to manage better your preventive maintenance program through your CMMS software.
1. Levels of Preventive Maintenance Compliance (PMC)
The core idea of preventive maintenance is the performance of proactive actions against unscheduled downtime in order to identify potential defects before they evolve into something more severe. Therefore schedules and on-time interventions are of critical importance. The preventive maintenance compliance score represents the percentage of planned preventive tasks that are performed within a defined time interval.
The following steps will help you establish the measurement of a company’s preventive maintenance compliance:
- Define scheduled and preventive maintenance tasks for each piece of equipment
- Implement preventive maintenance at the specified time
- Measure the percentage of tasks achieved in the defined time
- Communicate with your teams the result of all performed preventive maintenance interventions
Here is an example for the calculation of a preventive maintenance compliance:
1st day: 4 preventive tasks planned - 3 realized
2nd day: 4 preventive tasks planned - 2 realized
3rd day: 4 preventive tasks planned –1 realized
4th day: 4 preventive tasks planned - 3 realized
5th day: 4 preventive tasks planned - 4 realized
Your rate of completion of your preventive maintenance will be: (3 + 2 + 1 + 3 + 4) / (4 + 4 + 4 + 4 + 4) = 0.65 or 65% for the week.
The preventive maintenance rate can be automatically calculated in Mobility Work and efficiently replace your Excel sheets in case you are still using any. Results like these will help you determine if the established maintenance policy covers the needs of your organization or if you need to make any adjustments in order to obtain better results in terms of assets reliability.
2. Percentage of Planned Maintenance
As already mentioned above, there are 2 types of maintenance – planned and unplanned. Scheduled maintenance refers to operations that have been programmed after a certain amount of data has been taken into account. This data may include the intervention history of a piece of equipment, running time, failure time, spare parts and others.
The unplanned maintenance covers non-scheduled operations that often arise from a major emergency, critical machine down, etc. Unscheduled maintenance is expensive because it creates unnecessary costs for spare parts, maintenance resources, non-production hours, etc.
The planned maintenance percentage is the total planned maintenance time in your CMMS software over a date range over the total number of hours of a service performed by the technicians.
If you have planned 250 hours the previous month, and that 400 hours of maintenance have been done by your maintenance department, then your planned maintenance percentage will be 250/400 or 62.5%. This type of indicator can be easily measured with Mobility Work’s analytics tool.
Compared to unplanned maintenance, scheduled interventions will help you better manage your maintenance department while reducing operational costs. Since maintenance is planned, you can easily optimize the maintenance of your budget, forecast operation costs and optimize the time of maintenance technicians.
And last but not least, planned preventive maintenance can improve employees’ satisfaction since scheduled interventions are far less stressful than critical failure emergencies.
3. Critical percentage of planned maintenance
However, every maintenance professional knows that scheduled tasks can have very often a delay. Calculating the critical percentage of planned maintenance (indicating the delay of planned maintenance tasks compared to the maintenance schedule) will help you prioritize the most important operations that should be performed immediately.
The critical percentage of planned maintenance can be calculated as follows:
(Late days + type of period of the maintenance plan) / type of period of the maintenance plan * 100% of maintenance
Here are some examples:
- Monthly maintenance plan with 4 days delay: (4 + 30) / 30 * 100 = 113% criticality rate
- Annual maintenance plan with 10 days delay: (10 + 365) / 365 * 100 = 102% criticality rate
Calculating the critical percentage of scheduled maintenance operations helps you prioritize maintenance plans in your CMMS.
Preventive maintenance is proven far less expensive than unplanned interventions. The implementations of the 3 important indicators, discussed in this article – levels of preventive maintenance compliance, percentage of planned maintenance and critical percentage of planned maintenance – positively impact the management of your maintenance and improve quickly the outcome. All data related to these 3 indicators can be successfully collected, stored and analyzed with Mobility Work. Furthermore, the next-gen CMMS streamlines your entire maintenance performance in order to improve equipment reliability and the plant’s overall production.