Measuring Maintenance Effectiveness or Performance
PlantRun can provide highly accurate maintenance KPI’s in real-time for improved maintenance effectiveness or performance.
This is achieved by recording all downtime events or stoppages to one second accuracy. Any downtime period can have multiple reasons and comments assigned to it. In this way any breakdown and sequence of actions to rectify it can be measured and reported.
As an example, referencing the diagram below, PlantRun records whenever a machine stops. If the stoppage is serious and requires attention from an engineer either the machine operator calls using the machines operator terminal or a call is automatically generated after a preset time.
In either case this may be via a pre recorded public address message, SMS text to mobile phone or email. PlantRun takes account of the number of engineers on shift and machine priority to minimise engineer calls.
| MTBF |
Mean Time Between Failures |
MODT |
Mean Operative Downtime |
|
| MTTR | Mean Time to Repair | MPDT | Mean Preventative Maintenance Downtime | |
| MIT | Mean Idle Time | MOT | Mean Operational Time | |
| MWT | Mean Waiting Time | MTTM | Mean Time to Maintain | |
| MTTF | Mean Time to Failure | MUT |
Mean Uptime |
The period between the fault start (far left) and engineer call is MODT. When an engineer logs on at the machine the wait time is recorded - MWT. If there is time lost in logistics such as awaiting parts this can be sub assigned as MLDT.
When the fault is repaired the engineer logs off from the machine to give MTTM. Any idle time until a machine operator logs on to the machine to begin production is recorded as MIT.
This allows reliability and maintainability KPI's to be reported, tracked and trended to enable improved maintenance performance and effectiveness. Setup and changeover sequences can be measured and tracked in the same way.
Continuous Condition Monitoring
Continuous condition monitoring of a wide range of parameters affecting equipment maintenance intervals such as hours run, number of cycles or operations, total throughput, time spent under load etc. is also possible
PlantRun can calculate when a pre-determined level of any monitored parameter has been passed. The system then alerts that maintenance is required via an on screen message, report generation, email or SMS text message. This allows maintenance to be optimised based on actual equipment work load or usage.
Condition monitoring parameters can also be graphed against process data to detect changes over time that might indicate problems associated with specific machines allowing planned repair rather than breakdown maintenance.
Reference: www.plant-maintenance.com/articles/Availability_Definition.pdf
