Title: Draft EN 15341 Maintenance - Maintenane Key Performance Indicators ...
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Latest date for receipt of comments: 31 January 2006 Responsible committee:
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Title:
Draft EN 15341 Maintenance - Maintenane Key Performance Indicators
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EUROPEAN STANDARD NORME EUROPÉENNE
DRAFT prEN 15341
EUROPÄISCHE NORM September 2005 ICS
English Version
Maintenance - Maintenance Key Performance Indicators
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 319. If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to provide supporting documentation. Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36
© 2005 CEN
All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.
B-1050 Brussels
Ref. No. prEN 15341:2005: E
prEN 15341:2005 (E)
Contents
Page
Foreword..............................................................................................................................................................3 1
Scope ......................................................................................................................................................3
2
Normative references ............................................................................................................................3
3
Terms and definitions ...........................................................................................................................3
4
Maintenance Performance ....................................................................................................................4
5 5.1 5.2
System of indicators .............................................................................................................................4 Objectives...............................................................................................................................................4 Architecture of key indicators ..............................................................................................................5
6 6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 6.2.3 6.3 6.3.1 6.3.2 6.3.3
Indicators................................................................................................................................................5 Economical Key Indicators...................................................................................................................6 LEVEL 1 ..................................................................................................................................................6 LEVEL 2 ..................................................................................................................................................6 LEVEL 3 ..................................................................................................................................................7 Technical key indicators .......................................................................................................................8 LEVEL 1 ..................................................................................................................................................8 LEVEL 2 ..................................................................................................................................................8 LEVEL 3 ..................................................................................................................................................9 Organisational indicators ...................................................................................................................10 LEVEL 1 ................................................................................................................................................10 LEVEL 2 ................................................................................................................................................10 LEVEL 3 ................................................................................................................................................10
7 7.1 7.2 7.3 7.4 7.4.1 7.4.2 7.4.3 7.4.4
Methodology for the selection and use of key performance indicators for maintenance ...........12 Defining the objectives which characterise the maintenance management process ..................12 Selecting the relevant indicators .......................................................................................................13 Defining and collecting the necessary basic data ...........................................................................13 Calculating the indicators and selecting the type of representation .............................................14 Frequency of calculating of the indicators .......................................................................................14 Type of presentation ...........................................................................................................................14 Test and validation ..............................................................................................................................14 Analysis of the results ........................................................................................................................14
Annex A (normative) Key Indicators Factors List..........................................................................................15
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prEN 15341:2005 (E)
Foreword This document (prEN 15341:2005) has been prepared by Technical Committee CEN/TC 319 “Maintenance”, the secretariat of which is held by UNI. This document is currently submitted to the CEN Enquiry.
Introduction This European Standard provides the “Maintenance Key Performance Indicators” to support management in achieving maintenance excellence and utilize technical assets in a competitive manner. The majority of these indicators are applicable to all industrial and supporting facilities (buildings, infrastructure, transportation, distribution, networks, etc). The indicators should be used to: a)
measure the status;
b)
compare (internal and external benchmarks);
c)
diagnose (analysis of strengths and weaknesses);
d)
identify objectives or goals;
e)
plan improvement actions;
f)
continuously measure the changes over time.
1
Scope
This European standard describes a system for management of Key Performance Indicators to measure maintenance performance in the framework of the influencing factors such as the economical, technical and organizational aspects, to appraise and to improve efficiency and effectiveness in order to achieve a excellence in maintenance of Technical Assets.
2
Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments). EN 13306:2001, Maintenance-Terminology.
3
Terms and definitions
For the purposes of this standard the terms and definitions included in EN 13306 apply together with those listed in Annex A.
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4
Maintenance Performance
Maintenance Performance is the result of the utilization of resources in providing actions to retain an item in, or restore it to, a state in which it can perform the required function. It can be expressed as an achieved or expected result. The Maintenance Performance is dependent upon both external and internal influencing factors such as: location, culture, transformation and service processes, size, utilization rate and age and is achieved by implementing corrective, preventive and improvement maintenance, using labour, information, materials, organisational methodologies, tools and operating techniques. Maintenance Performance is an outcome of complex activities which can be evaluated by appropriate indicators to measure both the actual and expected results.
5
System of indicators
This system of key performance indicators is structured into three groups (economic, technical and organisational) in order to cover all aspects of maintenance. Any indicator can be evaluated as a ratio between factors (numerator and denominator) measuring activities, resources or events, according to a given formula. The indicators are used to measure any quantitative aspect or characteristic of an indenture level and for homogeneous comparison. Whenever a factor is defined by using the words “internal” or “external”, the derived indicator, should also be used only for “internal” or “external” influences, as appropriate.
5.1
Objectives
When the actual or expected performance is not satisfactory it encourages the management to define objectives and strategies to improve from an economic, technical or organisational point of view using this system of indicators which allows the organisation to: a)
measure the status;
b)
evaluate the performance;
c)
compare performance;
d)
identify strengths and weaknesses;
e)
set objectives;
f)
plan strategies and actions;
g)
share the results in order to inform and motivate people;
h)
control progress and changes over time.
The indicators can be used:
on a periodic basis, for instance by preparing and following-up a budget, and during the assessment of the performance:
on a spot basis, for instance within the framework of specific audits, studies and/or benchmarking.
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The period of time to be considered for measurement depends on the company policy and management approach.
5.2
Architecture of key indicators
The following matrix illustrates the external and internal factors that influence maintenance performance and consequently the three groups of key indicators: External factors are variable conditions outside of the company management control. Internal factors are referred to group, company, factory, plant outside of the maintenance management control, but inside of the company management control. When using the key maintenance performance indicators, it is important to consider these influencing factors as prerequisites in order to avoid misleading evaluations and comparisons through not having homogeneous conditions.
Maintenance Influencing Factors and Maintenance Key Performance Indicators External influencing factors
Indicator Level
Location Society Culture National Labour Cost Laws Regulations Sector / Branches
Market Situation Company Culture Process Severity Product Mix Plant Size Utilization Rate Age of Plant Criticallity
6
Indicator Group
Internal influencing factors
Economic indicators Technical Indicators Organizational Indicators
Level 1
Level 2
Level 3
E1 E2 E3 E4 E5 E6
E7 E8 E9 E10 E11 E12 E13 E14
E15 E16 E17 E18 E19 E20 E21 E23 E24
T5 T6
T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 T19 T20 T21
O9 O10
O11 O12 O13 O14 O15 O16 O17 O18 O19 O20 O21 O22 O23 O24 O25 O26
T1 T2 T3 T4
O1 O2 O3 O4 O5 O6 O7 O8
Indicators
When calculating the indicators, denominator and numerator factors shall be referred to the same activity/item and to the same period of time (year, quarter, month, etc.). These factors are explained in the terminology sheet at the end of this document. Most of the indicators can be used at different levels, depending on whether they are used to measure the performance of a plant production, one production line, or a given equipment or item, etc.
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The indicators in this standard are structured in levels which represent their breakdown structure. Indicators below level one are a detailed description of indicators at higher level. The indicators in this standard are numbered by level as a means of identification and not as an indication of importance. These indicators can be referred to the internal maintenance, external maintenance or both. The term “Time” is in general used to describe time units related to the equipment and its performance. The terms “Hours” or “Man hours” describe the hours delivered to the maintenance activities.
6.1 6.1.1
Economical Key Indicators LEVEL 1
E1
Total Maintenance Cost Assets Replacement Value
x 100
E2
Total Maintenance Cost Added value plus external costs for maintenance
x 100
E3
Total Maintenance Cost Output of operations
E4
Total Maintenance Cost Production transformation cost
E5
Total Maintenance Cost + unavailability costs related to maintenance Output of operations
E6
6.1.2
x 100
Availability related to maintenance Total Maintenance Cost
LEVEL 2
E7
Average inventory value of maintenance materials Asset Replacement Value
x 100
E8
Total internal personnel cost spent in maintenance Total Maintenance Cost
x 100
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E9
Total external personnel cost spent in maintenance Total Maintenance Cost
x 100
E10
Total contractor cost Total maintenance cost
x 100
E11
Total cost of maintenance materials Total maintenance cost
x 100
E12
Total cost of maintenance materials Average inventory value of Maintenance materials
E13
Cost for indirect maintenance personnel Total Maintenance Cost
E14
6.1.3
= Warehouse turnover x 100
Total Maintenance Cost Total Energy Used
LEVEL 3
E15
Corrective maintenance cost Total Maintenance Cost
x 100
E16
Preventive maintenance cost Total Maintenance Cost
x 100
E17
Condition based maintenance cost Total Maintenance Cost
x 100
E18
Predetermined maintenance cost Total Maintenance Cost
x 100
E19
Improvement maintenance cost Total Maintenance Cost
x 100
E20
Maintenance shutdown cost Total Maintenance Cost
x 100
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E21
Cost of training for maintenance Number of maintenance personnel
E22
Total Mechanical maintenance contractor costs Total maintenance contractor costs
E23
Total Electrical maintenance contractor costs Total maintenance contractor costs
E24
Total Instrumentation maintenance contractor costs Total maintenance contractor costs
6.2 6.2.1
T1
Technical key indicators LEVEL 1
Total Operating time Total Operating time + Down time due to maintenance
T2
T3
T4
6.2.2
Achieved up time during required time Required time
x 100 (availability related to maintenance) x 100 (operational availability)
Number of failures due to maintenance creating environmental damage Calendar time Number of injuries for people due to maintenance Calendar time
LEVEL 2
T5
Total operating time (Total operating time + Down time related to failures)
T6
Total operating time (Total operating time + Down time related to planned and scheduled maintenance)
8
unit of value / person
x 100
x 100
prEN 15341:2005 (E)
6.2.3
LEVEL 3
T7
Preventive maintenance time causing down time Total down time related to maintenance
x 100
T8
Predetermined maintenance time causing down time Total down time related to maintenance
x 100
T9
Condition based maintenance time causing down time Total down time related to maintenance
x 100
T10
Number of failures causing injury to people Total number of failures
x 100
T11
Number of failures causing potential injury to people Total number of failures
x 100
T12
Number of failures causing damage to the environment Total number of failures
x 100
T13
Number of failures causing potential damage to environment x 100 Total number of failures
T14
Total Operating time Number of maintenance work-orders causing down time
T15
Total Operating time Number of maintenance work-orders
T16
T17
T18
T19
T20
Total operating time Number of failures
=
MTTF
Number of failures Asset Replacement Value Number of systems covered by a critical analysis Total number of systems
x 100
Man hours used for planning in a systematic maintenance planning process (Initial planning) Total internal maintenance personnel man hours Planned and scheduled maintenance time causing production down time Planned and scheduled total maintenance time requiring down time
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T21
6.3 6.3.1
Total time to restore Number of failures
=
MTTR
Organisational indicators LEVEL 1
O1
Number of internal maintenance personnel Total internal employees
x 100
O2
Number of indirect maintenance personnel Number of internal maintenance personnel
x 100
O3
Number of indirect maintenance personnel Number of direct maintenance personnel
x 100
O4
Production operator maintenance man hours Total direct maintenance personnel man hours
O5
Planned and scheduled maintenance man hours Total maintenance man hours available
x 100
O6
Number of injuries to maintenance personnel Total maintenance personnel
x 10000 (frequency rate)
O7
Man-hours lost due to injuries for maintenance personnel Total man hours worked by maintenance personnel
O8
Internal man-hours used for continuous improvement Total internal maintenance personnel man hours
6.3.2
x 10000
LEVEL 2
O9
Production operator maintenance man hours Total production operators man hours
x 100
O10
Direct maintenance personnel on shift Total direct maintenance personnel
x 100
6.3.3
O11
10
LEVEL 3
Immediate corrective maintenance time Total down time related to maintenance
x 100
(severity rate)
prEN 15341:2005 (E)
O12
Internal mechanical man hours Total internal direct maintenance personnel man hours
x 100
O13
Internal electrical man hours Total internal direct maintenance personnel man hours
x 100
O14
Internal instrumentation man hours Total internal direct maintenance personnel man hours
x 100
O15
Number of internal Multi-skilled maintenance personnel Number of internal maintenance personnel
x 100
O16
Corrective maintenance man hours Total maintenance man hours
x 100
O17
Immediate Corrective maintenance man hours Total maintenance man hours
x 100
O18
Preventive maintenance man hours Total maintenance man hours
x 100
O19
Condition based maintenance man hours Total maintenance man hours
x 100
O20
Predetermined maintenance man hours Total maintenance man hours
x 100
O21
Overtime internal maintenance man hours Total internal maintenance man hours
x 100
O22
Number of work orders performed as scheduled Total number of scheduled work orders
x 100
O23 Number of maintenance internal personnel man hours for training Total internal maintenance man hours O24
O25
x 100
Number of direct maintenance people using software Number of internal direct maintenance personnel Total man hours spent by direct personnel on planned and scheduled activities Total man hours planned and scheduled to direct personnel
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O26
Number of the spare parts supplied by the warehouse as requested Total number of spare parts required by maintenance
7 Methodology for the selection and use of key performance indicators for maintenance 7.1
Defining the objectives which characterise the maintenance management process
In order to select relevant indicators, the first step is to define the objectives to be reached at each level of the enterprise. At the company level, the requirement is to identify how maintenance can be managed in order to improve global performance (profits, market shares, competitiveness etc). In this case, the most efficient means of maintenance improvement shall be determined. At the systems level and production lines, the maintenance objectives can address some particular performance factors, which have been identified through previous analysis, such as:
improvement of availability;
improvement on cost-effective maintenance;
retaining the health, safety and environment preservation;
improvement in cost-effective management of the value of the maintenance inventory;
control of contracted services;
etc.
At the equipment level, machines or types of machines, better control of the following may be desirable:
reliability;
costs;
duration of stops;
etc.
The objectives may also consist of giving advice for decisions concerning:
investments;
the duration of utilisation;
the choice of a strategy such as the recourse to contractors;
etc.
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7.2
Selecting the relevant indicators
When the objectives have been defined, and the performance parameters to be measured have been identified, the next step is to find the indicators which allow measuring these parameters. When selecting the indicators for maintenance management, the system could for example include:
the capacity of maintaining the equipment which includes:
the maintainability of the equipment;
the logistic support (spare parts, tools, documentation, …);
the work organisation;
the reliability of the equipment;
the efficiency of the maintenance activities;
the safety;
etc.…
An indicator is relevant when its value, or its evaluation is correlated with the evaluation of the performance parameter to be measured. A relevant indicator shall be one element of decision making. That means that the data which constitute this indicator shall have a relation to the defined objective. This link can be proved by analysis or through interview of experts. Statistical techniques can also be utilised in order to ascertain correlations between indicators. In the search for relevant indicators, two approaches are possible:
the first consists of choosing from amongst list of existing indicators those, which after analysis, fulfil the requirements;
the second starts from the following methods which begin with the evaluation of the various processes of maintenance which can be obtained through functional analysis.
In practice, both approaches can be used.
7.3
Defining and collecting the necessary basic data
It is necessary to precisely define:
the data to be collected in order to determine the values required for the indicator;
the measurement method (operating mode);
the tools required for the measurement (documents, counters, sensors, analysers, computerized maintenance management system, etc.).
In order to make the possible evaluation and comparisons easier, it is obligatory that the collected data are in conformity with the standardised definitions when they exist (see EN 13306). If the definition does not exist, it will be necessary to derive such a definition.
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7.4
Calculating the indicators and selecting the type of representation
7.4.1
Frequency of calculating of the indicators
Independently from the collection of the data, the frequency of the calculation could be predetermined. (For instance, it is possible to evaluate a quarterly indicator with monthly collected data) The frequency of data collection shall be adapted to:
the availability and time delay of the relevant data;
the changes over time (gradient, seasonality, etc.) of the measured performance;
the reactivity of the system to the actions undertaken.
7.4.2
Type of presentation
The utilisation of indicators generally requires a graphical presentation according to the required utilisation and to the importance of the series of data. 7.4.3
Test and validation
Before the calculation is used as a routine, each indicator will be calculated by using a representative sample during a significant period which will allow validation of:
the methods of collecting and processing the data;
the methods of calculation and making graphical presentation;
the analysis and utilisation of these indicators.
7.4.4
Analysis of the results
The next steps, that are outside the scope of this standard, are to build scorecards to analyse and to take the required actions.
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Annex A (normative) Key Indicators Factors List
Indicators
Factors
Total Maintenance Cost
E1
Definitions Total Maintenance Cost (often on annual base and related only to the Maintenance activities performed on the asset/item) includes costs referred to: • Wages, salaries and overtimes for managerial, supervision, support staff and direct staff • Payroll added costs for the above mentioned persons (Taxes, Insurance, Legislative contributions) • Spares and materials consumables charged to maintenance (including freight costs) • Tools and equipments (not capitalized or rented) • Contractors, rented facilities • Consultancy services • Administration costs for maintenance • Education and training • Costs for maintenance activities carried out by production people • Costs for transportation, hotels, etc • Documentation • CMMS (software) and Planning Systems • Energy and utilities • Depreciation of maintenance capitalized equipments and workshops, warehouse for spare-parts Exclusions: Costs for product changeover or transaction time (e.g. Exchange of dies) Depreciation of strategic spare parts Downtime costs
Asset Replacement Value (Plant Replacement Value)
The Asset Replacement Value (ARV) is defined as the amount of capital that would be required to replace the Asset. This is not the book value nor the current cost accounting value nor the cost to build a state-of-the-art replacement. ARV is an estimate of the current costs to replace in kind what now exists. (In industry ARV is usually the Plant Replacement Value) (ARV can be equivalent to the insurance value.)
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Indicators
E2
E3
Total Maintenance Cost
(see E1)
Added value plus external costs for maintenance
Production value less the value of raw materials-utilitiesservices purchased plus external cost of maintenance.
Total Maintenance Cost
(see E1)
Output of operations Total Maintenance Cost
E4
Definitions
Factors
Production transformation cost
Quantity of output issued by an asset/item (tons, litres, etc.). (see E1) Total cost required by an asset/item to transform a material incoming into a product/service, excluding raw materials and packaging auxiliary materials. (see E1) for Total Maintenance Cost The unavailability costs related to maintenance is Down time due to maintenance multiplied with the average value of a time unit of lost production/service of the asset/item.
E5
Total Maintenance Cost + unavailability The unit value of time of lost production can be extra costs related to production cost for production at a later stage/time, or/and maintenance the value or the lost income from production during the asset/item’s Down state due to maintenance. (Value of the “hidden plant” due to maintenance) Output of operations (See E3)
E6
The time an item has been able to be in a state to perform a required function under given conditions at a given instant of time or during a given time interval, assuming that the required external resources are provided. (Note 1. This Availability related to ability depends on the combined aspects of the reliability, maintenance the maintainability and the maintenance supportability. Note 2. Required external resources, other than maintenance resources, do not affect the availability of the time.) (According to EN13306) Total Maintenance Cost
E7
(See E1)
Average inventory Average inventory value of maintenance materials (spare value of Maintenance parts, consumables, materials) on the respective period. materials Replacement Value (See E1) of respective Assets
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Indicators
Definitions
Factors
Cost of internal personnel engaged in maintenance activities. The internal personnel cost (including payroll added costs as shown in E1) spent on maintenance are composed by:
E8
a) Total internal personnel cost spent in maintenance b)
c)
Total Maintenance Cost
E9
Total contractor cost
E11
E12
E13
Total Maintenance Cost Total cost of maintenance materials
Costs of maintenance production people
activities
carried
out
by
(See E1)
(See E1) Sum of contractor invoices billed for their maintenance activities spent on the asset/item. (See E1) Costs of the maintenance materials (spare parts, consumables, materials) consumed in a period.
Total Maintenance Cost
(See E1)
Total cost of maintenance materials
(See E11)
Average inventory value of Maintenance (See E7) materials Cost for indirect maintenance personnel Total Maintenance Cost
E14
Indirect Personnel (Managers, Staff and clerks, Supervisors, Maintenance engineering personnel, Planning and scheduling personnel, Tools store men, Warehouse and store workers
Total external Cost of external personnel engaged in maintenance personnel cost spent activities. in maintenance Total Maintenance Cost
E10
Direct personnel are personnel working in the field, or workshops performing maintenance activities (usually referred to as “blue collar workers”)
Total Maintenance Cost Total Energy Used
Total cost related to indirect personnel (see E8, pos b.)
(See E1) (See E1) Power + gas + fuel oil + any other energy (energies measured all in kcal or all in MJoule as preferred)
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Indicators
E15
E16
E17
E18
E19
E20
E21
E22
Factors
Definitions
Corrective maintenance cost
Total cost for maintenance carried out after fault has occurred and intended to put an item into a state in which it can perform a required function.
Total Maintenance Cost
(See E1)
Preventive maintenance cost
Cost for maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning of an item.
Total Maintenance Cost
(See E1)
Condition based maintenance cost
The value of maintenance activities for condition based maintenance measured in terms of costs.
Total Maintenance Cost
(See E1)
Predetermined maintenance cost
Cost of preventive maintenance carried out in accordance with established intervals of time or number of units of use but without previous condition investigation.
Total Maintenance Cost
(See E1)
Improvement maintenance cost
Cost of maintenance carried out to improve the availability of the item, without changing the required function.
Total Maintenance Cost
(See E1)
Maintenance shut down cost
Costs of maintenance performed during shutdowns (outage scheduled for maintenance) of a plant or a factory (annual shutdown for example).
Total Maintenance Cost
(See E1)
Cost of training for maintenance
Cost for training for direct and indirect maintenance personnel (direct and indirect: see E8)
Number of maintenance personnel
Number of Direct Personnel plus number of Indirect Personnel (see E8).
Total Mechanical maintenance contractor costs Total maintenance contractor costs
E23
Total Electrical maintenance contractor costs Total maintenance contractor costs
18
Sum of the costs for the mechanical contractors activities
Sum of the costs by contractors for the mechanical, electrical and instrumental contractors activities. Sum of the costs for the electrical contractors activities.
(See E22)
prEN 15341:2005 (E)
Indicators
E24
Total Instrumentation Sum of the costs for the instrumentation contractors activities. maintenance contractor costs Total maintenance contractor costs Total operating time
T1
Definitions
Factors
Down time due to maintenance
(See E22) The time interval during which an item is performing its required function (see EN 13306:2001, Clause 9.3). Time interval during which an item is in a down state due to maintenance (see EN 13306:2001, Clauses 9.2 and 9.3). Up time: Time interval during which an item is in up state (See EN 13306:2001, Clauses 9.1 and 6.7).
Up state: State of an item characterized by the fact that it can perform a required function, assuming that the external Achieved up time during required time resources, if required, are provided (see EN 13306:2001, Clause 6.7)
T2
To easily understand this definition with the support of a figure, please refer to EN 13306.
Required time
The time interval during which the user requires the item to be in a condition to perform a required function (see EN 13306:2001, Clause 9.11) To easily understand this definition with the support of a figure, please refer to EN 13306.
T3
Number of failures due to maintenance creating environmental damage Calendar time
T4
Number of injuries for people due to maintenance Calendar time
Numbers of failures caused by maintenance or lack of maintenance that have caused damage to the environment.
Time interval (years, months). Numbers of failures caused by maintenance or lack of maintenance that have caused injuries for people. Time interval (years, months).
Total operating time (See T1)
T5
Down time related to Total down time lost due to failures. failures Total operating time (See T1)
T6
Down time related to The total time of planned and scheduled maintenance works, which requires down time. planned and scheduled maintenance down time
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prEN 15341:2005 (E)
Indicators
T7
T8
T9
Factors
Definitions
Preventive maintenance time causing down time
Time interval during which an item is in a down state due to preventive maintenance.
Total down time related to maintenance
Time interval during which an item is in a down state due to maintenance.
Predetermined maintenance time causing down time
Time interval during which an item is in a down state due to predetermined maintenance.
Total down time related to maintenance Condition based maintenance time causing down time Total down time related to maintenance Number of failures causing injuries for people
(See T7)
Time interval during which an item is in a down state due to condition based maintenance. (See T7)
Number of failures that cause an injury for people which will result in one or more lost working days. Total number of failures.
T10 Total number of failures
Failure: termination of the ability of an item to perform a required function. NOTE 1: After failure the item has a fault, which may be complete or partial NOTE 2: "Failure" is an event, as distinguished from "fault", which is a state
T11
Number of failures causing potential injuries for people Total number of failures
T12
Number of failures causing potential damages for environment Total number of failures
20
(See T10)
Number of failures Number of failures that cause damage for environment. causing damages for environment Total number of failures
T13
Number of failures that could cause an injury for people.
(See T10) Number of failures that could cause damage for environment.
(See T10)
prEN 15341:2005 (E)
Indicators
Definitions
Factors Total operating time (See T1)
T14
It includes corrective and preventive maintenance workNumber of maintenance work- orders, as well as improvement work-orders, causing down orders causing down time. time Total operating time (See T1)
T15
Number of maintenance workorders
It includes all corrective and preventive maintenance workorders, as well as improving work-orders.
Total operating time (See T1)
T16
T17
T18
Total number of failures
(See T10)
Total number of failures
(See T10)
Assets Replacement (See E1) Value Number of systems analyzed and covered by a Number of systems methodology with the purpose to assess and reduce risk. covered by a critical For the definition of “system”, please refer to the specific analysis methodology used. Total number of systems
T19
Man hours used for planning in a systematic maintenance planning process. (Initial planning)
Total number of systems. For the definition of “system”, please refer to the specific methodology used. Planning means hours used for initial planning in a managed process. The planning process is performed according to a predefined procedure. Planning: Activities are defined in such a way that safety considerations, special tools or procedures, tolerance standards, required replacement parts or materials are defined with an estimate of the downtime and man hours required to complete the work. All this information is available to the first line maintenance staff performing the work before it starts.
Number of hours carried out by internal maintenance Total internal personnel. maintenance personnel man hours
T20
Planned and scheduled maintenance time causing production down time
This is the total calendar time spent on planned and scheduled maintenance works causing production down time.
Planned and scheduled total maintenance time requiring down time
The total time of planned and scheduled maintenance works which requires down time.
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prEN 15341:2005 (E)
Indicators
T21
This term is defined as the total time to restoration, Total time to restore regardless of planned or unplanned corrective maintenance. Total number of failures
O1
Number of internal maintenance personnel Total internal employees
O2
O3
O4
Definitions
Factors
(See T10) Internal (direct and indirect: see E8) maintenance personnel. Total internal personnel in the asset.
Number of indirect maintenance personnel
Number of internal indirect (see E8) maintenance personnel.
Number of internal maintenance personnel
(See O1)
Number of indirect maintenance personnel
(See O2)
Number of direct maintenance personnel Production operator maintenance man hours
Number of direct (see E8) maintenance personnel.
Maintenance man hours carried out by a user or operator.
Number of hours carried out by direct (see E8) Total direct maintenance personnel. maintenance personnel man hours Man hours by direct (see E8) maintenance personnel to be used on planned and scheduled activities (internal and external).
O5
Planned and scheduled maintenance man hours
Planning: Activities are defined in such a way that safety considerations, special tools or procedures, tolerance standards, required replacement parts or material are defined with an estimate of the downtime and man hours required to complete the work before it starts. Scheduling: To establish a time schedule, or the number of units of use, indicating when maintenance should be performed. (Planned and scheduled man hours could be man hours used for corrective maintenance, conditioned-based maintenance, performed maintenance and improvement maintenance).
Number of maintenance man hours (internal and external) Total maintenance available for maintenance activities (excluding holidays, man hours available training, etc…).
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prEN 15341:2005 (E)
Indicators
O6
O7
O8
Definitions
Factors Number of injuries for maintenance personnel
Number of injuries occurred to internal maintenance personnel, preventing them to further work for a day or more.
Number of internal maintenance personnel
(See O1)
Man-hours lost due to injuries for maintenance personnel
Internal maintenance man-hours lost due to injuries for internal maintenance personnel.
Total man-hours worked by maintenance personnel
Internal man-hours used for continuous improvements
Number of internal maintenance man hours actually produced.
Internal (direct and indirect: see E8) maintenance man hours used for continuous improvements, that is hours used for systematic critical analysis, for identification of improvement, for participation in projects and their preparations, as instructor for training and education internally and externally, or, finally, for safety, quality or environmental audit or schemes.
Number of hours carried out by internal maintenance Total internal personnel. maintenance personnel man hours
O9
Production operator maintenance man hours
Maintenance man hours carried out by a user or operator. (Thus maintenance carried out by people not under the maintenance department)
Total production Hours carried out for whatever activities by a user or operators man hours production operator. Direct maintenance personnel on shift
O10
O11
O12
Total direct maintenance personnel
It regards the direct (see E8) maintenance personnel that “work on shift”, on plant and services (on operation). Number of direct maintenance personnel.
Maintenance, which is carried out without delay after a Immediate corrective fault, has been detected to avoid unacceptable maintenance time consequences. Total down time related to maintenance Internal direct mechanical man hours
(See T7) It is referred to man hours from internal maintenance mechanical personnel.
Total internal direct Number of hours carried out by internal direct (see E8) maintenance maintenance personnel. personnel man hours
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prEN 15341:2005 (E)
Indicators
Definitions
Factors
Internal direct It is referred to man hours from internal maintenance electrical man hours electrical personnel.
O13
O14
O15
O16
O17
Total internal direct (See O12) maintenance personnel man hours It is referred to man hours from internal maintenance Internal direct instrumentation man instrumental personnel. hours Total internal direct (See O12) maintenance personnel man hours Number of internal multi-skilled maintenance personnel
Number of internal direct (see E8) maintenance personnel that operate as multi skill (at least more than one skill) maintenance personnel.
Number of internal maintenance personnel
(See O1)
Corrective maintenance man hours
Hours spent on corrective maintenance activities (internal and external).
Total maintenance man hours
Number of man hours carried out by internal and external maintenance personnel.
Immediate Corrective Man hours spent on immediate corrective maintenance maintenance man activities (internal and external). hours Total maintenance man hours
O18
Preventive maintenance man hours Total maintenance man hours
O19
O20
Man hours spent on preventive maintenance activities (internal and external). (See O16)
Condition based maintenance man hours
Man hours spent on condition-based maintenance activities (internal and external).
Total maintenance man hours
(See O16)
Predetermined maintenance man hours
Man hours spent on predetermined maintenance activities (internal and external).
Total maintenance man hours
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(See O16)
(See O16)
prEN 15341:2005 (E)
Indicators
O21
Definitions
Factors Overtime internal maintenance man hours
Number of man hours carried out by internal maintenance personnel during overtime.
(See T19) Total internal maintenance personnel man hours Number of work order which are technically complete in a Number of work orders performed as timeframe less than a given time after the estimate of its conclusion. scheduled
O22
O23
O24
Total number of scheduled work orders
Number of work order scheduled. Scheduling: To establish a time schedule, or the number of units of use, indicating when maintenance should be performed.
Number of hours used in training for all personnel (direct Number of and indirect: see E8) of maintenance service. maintenance personnel man hours for training Total maintenance man-hours
(See O16)
Number of internal direct maintenance personnel using software
Number of direct (see E8) maintenance personnel using maintenance software for any maintenance or asset management means (work-orders flow, bills of materials, planning, spare-parts warehousing, etc…).
Number of internal direct maintenance personnel
Internal direct (see E8) maintenance personnel.
Number of man hours spent by direct (see E8) personnel on planned and scheduled activities. Total man hours spent by direct personnel on planned and scheduled activities
Planning: Activities are defined in such a way that safety considerations, special tools or procedures, tolerance standards, required replacement parts or material are defined with an estimate of the downtime and man hours required to complete the work before it starts.
Total man hours planned and scheduled to direct personnel
Planning: Activities are defined in such a way that safety considerations, special tools or procedures, tolerance standards, required replacement parts or material are defined with an estimate of the downtime and man hours required to complete the work before it starts.
O25
Scheduling: To establish a time schedule, or the number of units of use, indicating when maintenance should be performed. Number of man hours planned for direct (see E8) personnel to planned and scheduled activities
Scheduling: To establish a time schedule, or the number of units of use, indicating when maintenance should be performed.
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prEN 15341:2005 (E)
Indicators
O26
Factors Number of the spare No need of definition. parts supplied by the warehouse as requested No need of definition. Total number of spare parts required by maintenance
26
Definitions
