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Author's profile photo Tajinder Singh

Key Performance Indicators (KPIs) in Plant Maintenance

In SAP Plant Maintenance implementations, often there is a need of the client to suggest KPIs/Metrics which could help them to gauge the performance of their maintenance team/assets. Many of the times client is already having some metrics/KPIs to gauge the performance but those are loosely defined; in many other times there are no well-defined KPIs identified.

This document will provide a list of KPIs that could be suggested to clients to monitor the performance of their maintenance team or company’s assets. Note that to calculate some of these KPIs custom reports/dashboards may need to be developed.

First of all let me explain the difference between a KPI and a metric. Many times both these terms get mixed and the client gets confused. A metric wrt Plant Maintenance is a number or a percentage which defines how maintenance team/assets are performing as compared to company objectives. A KPI is also a metric i.e. KPI is also a number or a percentage but KPI is a metric which has the power to provide to the management some recommendations to improve performance/reduce costs. So all KPIs are metrics but all metrics are not KPIs.

Let’s define some KPIs for Plant Maintenance. In order to make this more structured, let’s start with the basic steps in a typical maintenance scenario:

Problem Identification> Order Planning> Scheduling>Completion> Root Cause Analysis

We will define KPIs in all these areas one by one:

KPIs in Problem Identification:

 

  1. % or No. of Preventive Maintenance vs Reactive Maintenance Orders
  2. % or No. of Notifications in OSNO status for more than x days

      

KPIs in Order Planning:

 

  1. % or No. of Planned orders vs Unplanned orders/Emergency Orders
  2. % or No. of Work orders where actual cost/planed cost variances exceeds x %
  3. % or No. of Work orders in CRTD status for more than x days
  4. % or No. or Work orders delayed due to stock outs

     

KPIs in Order Scheduling:

 

  1. % of scheduled man-hours to total available man-hours per week/month
  2. % or no. of work orders where scheduled date is on or before expected date of start of work

   

KPIs in Order Completion:

  

  1. % or no. of work orders completed within x no. of days
  2. % or no. of work orders recalled i.e. work not completed as expected
  3. % or no. of notifications associated with work orders where cause/damage code is not filled
  4. % or no. or work orders executed internally vs by external vendor

KPIs in root cause analysis:

 

  1. Total maintenance cost per equipment category or maintenance cost per equipment category
  2. Ratio of planned maintenance costs vs actual maintenance costs
  3. Mean time to Repair (MTTR)
  4. Mean time between failures (MTBF)
  5. % Availability of equipment

         

Apart from these there are multiple queries/metrics that could be used to get a large number of metrics. Refer link below:

http://help.sap.com/saphelp_nw73/helpdata/en/09/da8853630b3d58e10000000a174cb4/content.htm?frameset=/en/86/018653aa9a6159e10000000a174cb4/frameset.htm&current_toc=/en/f8/018653aa9a6159e10000000a174cb4/plain.htm&node_id=35

 

As a good consultant, we should filter out the metrics and recommend only few critical KPIs so that the company is not overloaded with tons of data and metrics and is able to make critical business decisions using a handful of KPIs.

Thanks,

Tajinder

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      Author's profile photo Piyush Gupta
      Piyush Gupta

      Very nice document from solution designing point.....Can you share some doc on MTTR and MTBF.


      Regards,

      Piyush

      Author's profile photo Tajinder Singh
      Tajinder Singh
      Blog Post Author

      Hi Piyush,

      There is an already existing very good document on the same. Refer to this link below:

      MTTR, MTBR, Failure Rate, Availability and Reliability

      Hope this helps!

      Thanks,

      Tajinder

      Author's profile photo Former Member
      Former Member

      Hi Tajinder,

      Thanks for sharing the document, its well written.

      Could you help me over one issue over KPIs.

      I am aware of counts but can we provide % computation of orders or notification such as % of completed or open orders in Standard ECC?

      Regards

      Kaushik

      Author's profile photo Tajinder Singh
      Tajinder Singh
      Blog Post Author

      Hi Kaushik,

      Unfortunately, there are no standard reports available in ECC to provide % computation for orders/notifications. We need to go for a custom report.

      Thanks,

      Tajinder

      Author's profile photo Former Member
      Former Member

      Alright.... Thanks for info..Tajinder

      Author's profile photo Jogeswara Rao K
      Jogeswara Rao K

      Hello Kaushik,

      I developed (through ABAP) few such aggregate reports like:

      • Plan calls vs Fulfillment statistics and the percentage
      • Major Breakdowns vs RCA exercises done statistics and the Percentage (Based on Local definitions)

      And we can develop many such as per your KPIs there. Infoset Queries are not convenient tool for this, because we have to do aggregation using COLLECT statement. But for an ABAPer it is a simple job developing this, coming out with interesting output (Lines showing Totals, Averages, Percentages against Equipments or Locations or Planner Groups or Work Centers etc).

      Because of such many requirements, I always considered that ABAP support is an essential thing to do justice to client requirements.

      Regards

      KJogeswaraRao

      Author's profile photo Former Member
      Former Member

      Thanks Mr Rao for your valuable insights....

      Author's profile photo Former Member
      Former Member

      Dear Sir

      Could you send me KPI's  for Maintenance   like XLS form

      Best Regards ..

      Usama

      Author's profile photo Basavaraj Tenginakai
      Basavaraj Tenginakai

      Hi Tajinder

      Really nicely compiled. Very useful. Yes, we start searching in need of the hour. Thanks for sharing.

      Regards,

      Basavaraj

      Author's profile photo Manish G
      Manish G

      HI

      Its  really  helpful. kindly let us know  how to implement 5 why analysis in pm (configuration part & reports )