Support Reliability Strategies with Key Performance Indicators

Using IBM Maximo®

Julie Rampello

Director Business Development Solutions, Projetech

www.Projetech.com

Speaker Bio

• Julie Rampello

• Director, Business Development Solutions

• Projetech, Inc. www.Projetech.com

• Maximo Project Manager and Trainer for Projetech for 12 years

• Maximo Certified Deployment Professional

• Hobbies & Interests include: technology, data analytics, fitness, social media

Workshop Topics

• Reliability programs should support strategic corporate objectives

• Relevant Key Performance Indicators

– Measure program effectiveness

– Provide believable data

• KPI management and other Reporting options in Maximo

Reliability Programs• Must Meet Organizational Objectives

– Able to meet changing requirements for capacity, quality, reliability, and cost.

– Most importantly, activities must always focus on ROI.

• Data Opens the Door to Success– Using hard facts, you can link the physical facility to the core

business goals of your organization. – Typical links include the ability to help organizations meet new

and evolving safety, environmental, health, and regulatory requirements.

• What's Your Top Priority?– Focus on the "vital few" vs. the "trivial many.“– Instead of doing routine maintenance on every single system in

the building, prioritize your maintenance activities. – Data helps you decide what to perform and when to do it.

KPI’s

• Performance Indicator (PI’s)– Any indicator measuring the performance of a

business process, work team, individual, piece of equipment or plan in terms of its ability to meet its desired levels of performance. 1

• Key Performance Indicators (KPI’s) – Real-Time Measure– Measures the overall performance of a particular

strategy or improvement initiative

• Use them to monitor effectiveness of reliability programs.

1 The Maintenance Scorecard: Creating Strategic Advantage

Indicators

• Lagging indicators (KRI) use historic data to build a performance trend line. The trend shows progress and can be projected forward to forecast likely progress.

• Leading indicators (KPI) use historic data to monitor whether or not activities are producing good results.

• Use a mix of lagging indicators and leading indicators to provide a clear understanding of what is happening to the risk and performance of your operational assets through maintenance efforts

What are You Measuring?Maintenance Effectiveness

• Maintenance performance indicators reflect achievement and progress in meeting an agreed maintenance benchmark.

• Measure whether maintenance work successfully removes risk of failure from your plant and equipment.

• Define Useful and Relevant KPI’s & PI’s 1

– Identify causes of equipment failures– Effectiveness of PM / Predictive Maintenance (PdM)

activities– Measure effectiveness and efficiency of the Maintenance

Group– Measure the reliability improvement and operating risk

reduction results of the maintenance effort

Maintenance Effectiveness/Efficiency

Maintenance Effectiveness KPI’s

Mean time between failure (MTBF)

Mean time between repair (MTBR)

Overall Equipment Effectiveness (OEE)

Time to complete EM work Budget compliance

Maintenance Efficiency and other KPI’s

PM compliance % Corrective maintenance Maintenance overtime Inventory stock outs (Service

level) Safety, i.e., Lost time

All Kinds of Things to Measure!

Safety

What’s Needed?

• The information you need to manage your reliability programs should be right at your fingertips.

• If done correctly, your CMMS/EAM applications will be able to provide you with the information you need to analyze the success of your reliability initiatives.

• It is important to know where data sources reside, whether in Maximo or 3rd Party systems.

• Integrate when it makes sense.

Bad Data = Bad KPI

• Meaningful KPI’s need relevant, timely, accurate and consistent data.

• Whenever possible, eliminate human error factor.

• Leverage automated data collection sources such as PLCs, Building Automation Systems, and computers.

• Collect data “at the source” via handheld or mobile devices.

• Use barcodes wherever it makes sense.

KPI’s by Job Function

Maintenance Supervisor KPI Examples• Maintenance cost per unit produced • MTBFF (Mean Time Between Functional Failure) • Maintenance labor cost (measured against target) • Maintenance material cost (measured against target) • Maintenance contractor cost (measured against target) • Overtime - % • Absenteeism - % • # of discipline violations • # of safety incidents • # of days without loss time accidents • # of environmental incidents

Maximo KPI Features

• Can be created from KPI Manager or 1-Click from an end user application, such as Work Orders

• Can be graphical or list format

• Viewable on User’s Start Center (dashboard)

• Can link/drill down to other supporting KPI’s

• Shows trend lines

Sample Maximo User Start Center

KPI Graph Example

KPI List Example

Behind the Scenes

Other Reporting Options

• A good CMMS/EAM application will provide:

– Open source data access by third party applications

– Integrated and robust reporting applications

– User-friendly “ad-hoc” reporting tools for simple report design

– Ability to export data set results

Integrated Reporting

• Open Source Platform report applications

• Support robust reporting requirements (complex formulas/crosstabs, etc.)

• Maximo

– BIRT

– Cognos

– Optional integration with Crystal XI

Canned Maximo OEE %Reportby Site

OEE% by Site Report (available from Assets application)

Canned Maximo OEE% ReportBy Location

Canned Maximo OEE% ReportBy Asset/Equipment

Canned Maximo Report Asset Availability

Canned Maximo ReportsDetails of Asset Failures

Open Source Reporting

• Connect to “back end” via 3rd party applications:

– MS Excel

– MS Access

– SQL Query apps

– Crystal Reports

Example

Export Data Utilities

• On screen query results

• Canned and ad-hoc reports

Conclusion

• Reliability programs should support strategic corporate objectives

• KPI and other metrics should provide relevant, accurate and timely information to support reliability program success.

• Many KPI best practices resources available.

• Prioritize metrics.

• Maximo provides many reporting options to support Key Performance Indicator reporting.

Resources

• The Maximo Manager’s guide to Business Performance Management – Richard Taggs, Philip Sage, Monica Osana, Dante Tepora, John Mark de Asis, TEAM

Global

• The Seven Deadly Sins in Measuring Asset Reliability– Ricky Smith, CMRP

• The Maintenance Scorecard: Creating Strategic Advantage– Darryl Mather– http://www.reliabilityweb.com/rr/MSCRD.pdf

• KPI Dashboards (White Paper)– Mileo Group www.mileogroup.com

• Projetech YouTube channel– http://www.youtube.com/results?search_query=projetech+kpi&sm=3