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维护管理解释：提高效率、安全性和资产寿命

维护管理 从制造业到能源和公用事业、医疗保健、仓储和物流、国防、教育等众多行业都至关重要。这是提高运营效率、安全性和设备寿命的重要业务功能。

无论您是寻求完善策略的经验丰富的维护经理，还是旨在掌握基础知识的新手，本文都提供了宝贵的见解和实用的建议。

从探索不同类型的维护（例如预防性、预测性、纠正性等）到讨论该领域的最新技术趋势和软件，该指南充满了数据驱动的见解和专家建议，可帮助您降低维护成本并提高效率。

维护管理是监督和协调与组织内设施、设备、机械和其他资产的维护和保养相关的所有任务的过程。这包括制定维护计划、协调维护活动、管理备件库存以及确保所有设备得到适当维护，以防止故障并延长其使用寿命。

有效的维护管理有助于最大限度地减少停机时间、降低成本并确保所有资产以最高效率运行。对于任何在运营中依赖设备和机械的组织来说，这是一项基本功能。

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维护管理实践和策略

基于数据 工厂工程

组织利用各种策略、实践和工具进行维护管理。根据 Plant Engineering 2021 年工业维护报告：

预防性维护和预测性维护预计在未来几年将大幅增长。 2020年全球预防性维护软件市场规模为7.869亿美元，预计到2027年将达到16.75亿美元，2024年至2027年复合年增长率为11.4%。

根据 Future Market Insights 的数据，2023 年全球预测性维护市场价值为 96 亿美元，预计到 2024 年将达到 105 亿美元。预计从 2024 年到 2034 年，该市场将以 10.9% 的复合年增长率增长，到 2034 年将达到 802 亿美元。预测性维护越来越多地应用于各个领域，包括航空航天、能源、制造、运输和国防等。公司越来越努力降低维护成本并最大限度地减少停机时间，而预测性维护可以通过监控设备运行状况和优化维护活动来优化维护活动

在故障发生之前解决小问题。人工智能、机器学习、物联网和云计算的日益普及进一步推动了需求。

让我们回顾一下一些最常见的维护策略。

纠正性维护

纠正性维护，也称为反应性维护，是传统的维护管理方法。通过这种方法，当一台设备或机器出现故障时可以进行维护。

纠正性维护包括以下任务：

被动维护可能涉及计划外停机和紧急维修，因此与主动维护形式相比，它往往会对运营造成更大的破坏，并且成本更高。

并非所有故障都可以预防或预测，因此即使使用其他形式的维护，纠正性维护也是维护管理的重要组成部分。

然而，通过实施其他维护策略，例如预防性维护，公司可以减少故障和设备故障的可能性和频率，并延长设备的使用寿命。

预防性维护

预防性维护包括在发生故障之前对设备进行维护。它通常基于时间或使用间隔 - 自上次执行维护以来的时间或设备主动运行的时间量。

预防性维护包括以下任务：

通过在问题出现之前定期维修和检查设备，企业可以避免代价高昂的故障和停机。预防性维护还有助于优化设备性能并延长机械和设备资产的使用寿命。 

预防性维护需要仔细规划和安排，以确保维护活动高效、有效地进行。

预测性（基于状况）维护

预测性维护，也称为基于状态的维护，使用传感器和监控设备收集有关设备状况的数据。通过分析这些数据来预测设备何时可能发生故障，以便组织可以采取主动措施来防止故障发生。

预测性维护包括以下任务：

通过使用数据和分析来预测何时需要维护，企业可以在问题成为重大问题之前主动解决问题。这可以减少停机时间、降低维护成本并提高整体运营效率。

预测性维护依赖于高质量、大容量的数据，可能需要对传感器、物联网设备、数据存储和分析软件进行大量初始投资。然而，通过仔细规划，长期效益是巨大的。

据UpKeep称，预测性维护的使用率从2017年的47%增加到2018年的51%。调查时，80%的制造工厂使用了预防性维护，超过50%的工厂使用了带有分析工具的预测性维护。

基于数据 魔多情报

预测性维护的使用持续增长。根据 Mordor Intelligence 的数据，2024 年机器状态监测市场估值预计为 12.5 亿美元。预计未来五年复合年增长率为 9.65%，到 2029 年达到 19.7 亿美元。

除了越来越多地采用预测性维护策略之外，由于跨行业的数字化转型以及物联网和人工智能技术的进步增强了监控能力，对远程监控的需求增加也推动了机器状态监控市场的增长。

规范性维护

规范性维护比预测性维护更进一步。它涉及使用高级分析、机器学习算法和人工智能来分析来自各种来源的数据，不仅预测潜在问题，还规定具体的维护操作来解决这些问题并优化维护流程。

这些建议可以包括关于执行维护的最佳时间、要执行的具体维护任务以及执行这些任务的资源的最佳分配的建议。规范性维护旨在实时优化维护决策，提高运营效率并降低成本。

规范性维护涉及以下任务：

该策略可帮助组织最大限度地减少停机时间、延长设备的使用寿命、提高安全性并优化维护成本。

以可靠性为中心的维护 (RCM)

以可靠性为中心的维护 (RCM) 可确保系统继续按预期运行并满足用户的需求。这种维护方法的重点是通过分析潜在的故障模式及其后果来保持设备或机械的功能。

以可靠性为中心的维护涉及以下任务：

通过识别最关键的组件并相应地安排维护任务，组织可以优化其维护实践并降低代价高昂的故障风险。 RCM 有助于延长资产的使用寿命、提高运营效率并提高组织的整体生产力。

全面生产维护 (TPM)

全面生产维护 (TPM) 是一种主动的维护方法，旨在最大限度地提高生产设备的效率。它强调了让所有员工参与维护过程的重要性，鼓励操作人员对其设备的维护负责并进行日常维护以防止故障。

全面的生产维护涉及以下活动：

实施TPM需要组织各个层面（从高级管理层到一线操作人员）的共同努力。通过创建主动维护和员工参与的文化，组织可以最大限度地减少停机时间、降低维护成本并提高整体绩效。

为了帮助您掌握所有维护活动，我们创建了这些专家清单：

先进的维护技术如何降低维护成本

屏幕截图 NIST

维护成本因地理区域和行业而异，因此很难准确估计。研究人员之间的估计也有所不同，因为计算成本时使用的指标不同。例如，一项研究估计维护成本占产品生产成本的 15% 至 70%，而另一项研究表明维护成本占总拥有成本的 37%。  

根据 Plant Engineering 的 2021 年工业维护报告，41% 的工厂将超过 10% 的年度运营预算分配给维护任务、服务和设备，而 46% 的工厂分配高达 10%：

维护成本无疑很高，但维护不足的后果更为严重。根据 Plant Engineering 于 2022 年 11 月发布的维护管理软件采购注意事项报告，计划外停机的平均成本为 108,708 美元。超过三分之一的受访者 (38%) 表示，其工厂意外停机的成本低于每小时 50,000 美元，而 8% 的受访者表示每小时成本超过 300,000 美元。

基于数据 工厂工程

在 2021 年报告中，Plant Engineering 还向受访者询问了工厂意外停机的主要原因。 42% 的受访者认为设备老化是主要原因，这一比例较 2020 年的 34% 有所增加。导致计划外停机的其他主要原因包括：

根据 Plant Engineering 的 2021 年工业维护报告，工厂平均每周花费 33 小时用于维护相关任务。根据 Plant Engineering 的调查，以下是工厂在维护相关任务上花费的小时数的具体细目：

根据 UpKeep 的说法，运行到故障点的设备的成本是定期维护的设备的 10 倍，并且每推迟 1 美元的维护就可能导致 4 美元的资本更新成本。

使用预防性和预测性维护策略可以帮助公司实现显着的成本节约、减少停机时间和其他好处。 UpKeep 报告称，预测性维护比预防性维护可节省 8-12%，比反应性维护可节省高达 40%。

美国国家标准与技术研究院 (NIST) 发布的 2020 年报告评估了美国制造商在离散制造领域因维护策略不充分而导致的机械维护成本和损失（NAICS 321-339，不包括 NAICS 324 和 325）。报告称，“2016年NAICS 321-339（不包括324和325）的机械维护支出估计为573亿美元。可预防的维护问题造成的损失达1191亿美元。”

该报告进一步解释道，“在依赖被动维护的企业中，排名前 25% 的企业的停机时间是排名后 25% 的企业的 3.3 倍。它们的缺陷数量也增加了 16.0 倍，由于维护缺陷导致的销售损失增加了 2.8 倍，由于维护延误导致的销售损失增加了 2.4 倍，并且由于维护问题导致库存增加了 4.9 倍。”

可预防的维护问题造成的 1191 亿美元损失包括：

在本研究纳入的美国制造商中，估计有 134.1 人受伤和 0.4 人死亡与维护问题有关。这相当于每百万员工估计有 16.03 人受伤和 0.05 人死亡。

本研究中的制造商在 2016 年采用了先进的维护策略，获得了：

基于数据 NIST

主要依靠预防性和预测性维护（定义为反应性维护低于 50%）的制造商实现了显着的效益。使用预测性维护策略的前 50% 的制造商经历过：

平均而言，在预防性或预测性维护方面投入更多的制造商会经历：

维护管理的好处

维护管理可以通过多种方式使您的组织受益，并且可以显着影响其整体成功。以下是实施有效的维护管理计划的一些最大好处。  

维护管理挑战

维护管理对于确保所有设备最佳运行至关重要。然而，组织在日常运营中经常面临与维护管理相关的一些挑战。

预算限制

组织经常面临财务限制，这可能会影响其执行必要维护的能力。由于预算有限，维护经理可能无法获得有效维护设备和设施所需的资源和工具。这可能会导致维修延误、停机时间增加，并最终降低生产率。

维护管理中预算限制的最大风险之一是推迟维护活动以削减成本的诱惑。虽然这可能会带来短期节省，但从长远来看可能会导致更大的问题。推迟维护可能会导致设备故障、安全隐患、维修成本增加和设备寿命缩短。

预算限制还会限制维护经理投资新技术和培训计划的能力，而从长远来看，这些技术和培训计划可以提高维护效率并降低成本。如果没有适当的投资，维护团队可能很难跟上最新的行业趋势和最佳实践。

平衡预防性维护与反应性维护

平衡预防性维护与反应性维护是维护管理的主要挑战之一。如本指南前面所述，预防性维护涉及安排定期维护任务以防止设备故障，而反应性维护涉及仅在设备发生故障时才修复设备。

在两者之间找到适当的平衡可能具有挑战性。很难预测设备何时会发生故障，从而很难确定适当的维护计划。这可能会导致设备过度维护，导致成本增加，或者设备维护不足，导致更频繁的故障。

在平衡预防性维护和反应性维护时，资源分配也可能是一个挑战。组织必须有效地分配资源，以确保有效地执行这两种类型的维护。由于资源有限且优先事项相互竞争，这可能很困难。

管理备件库存

拥有合适的备件对于最大限度地减少停机时间和保持设备平稳运行至关重要。然而，管理和跟踪备件库存可能非常复杂且耗时，特别是对于拥有大量资产的组织而言。

典型的维护部门可能有数百甚至数千个不同的库存零件，每个零件都有自己独特的零件编号、供应商和现有数量。手动跟踪所有这些零件可能会导致库存盘点和订购出现错误。

供应商的交货时间和交货可靠性增加了挑战。如果零件缺货或延迟交付，可能会影响设备的正常运行时间和维护计划。因此，维护经理必须与可靠的供应商保持良好的关系，并制定应急计划，以便在需要时快速获取零件。

对零件的需求也可能是不可预测的。设备故障随时可能发生，导致突然需要可能没有库存的零件。这可能会导致紧急订购，这可能既昂贵又耗时。

另一方面，过时或过剩的库存也是问题。如果设备升级或更换，零件可能会过时，导致零件闲置在架子上。

过多的库存会占用资金并占用宝贵的存储空间。因此，维护经理应定期检查库存水平并处理废弃零件。

实施强大的库存管理系统并定期审核备件有助于确保在需要时提供正确的零件，并最大限度地减少发生意外问题时的停机时间。 

资产标签和条形码标签有助于库存控制，并帮助维护技术人员在需要时找到正确的零件。例如，仓库货架标签使维护人员可以轻松快速地找到特定零件的正确存储位置。

容器、托盘、LPN、手提袋和托盘条形码标签可用于为存储容器添加标签。维护技术人员只需扫描条形码标签即可轻松识别特定部件及其兼容的设备。

基础设施老化

管理老化的基础设施，同时最大限度地减少停机时间并确保安全也是维护管理中的一个突出挑战。随着设备和设施的老化，它们可能需要更频繁且成本更高的维护。

老化的基础设施更容易恶化和故障，需要昂贵的维修和更换。这可能会导致预算和资源紧张，使维护经理难以满足老化基础设施的维护需求。

此外，许多旧的基础设施系统是使用现在被认为过时或低效的技术和材料建造的。这可能会导致很难找到替换零件和熟悉过时技术的熟练工人，从而导致维修时间更长和成本更高。

基础设施老化也可能构成安全隐患。随着基础设施系统随着时间的推移而恶化，它们的可靠性可能会降低并且更容易出现故障。这可能对公众以及负责维护基础设施的工人构成危险。

日程安排和计划

有效的维护需要仔细规划和安排，以尽量减少对运营的干扰。平衡定期维护活动与意外维修并确保工作在指定时间范围内完成可能很困难。

例如，设备可能会意外故障，需要立即维护。这可能会扰乱计划的维护计划，并要求维护团队在最后一刻确定任务的优先级并重新安排任务。在维护安排和规划方面，有限的资源会带来另一个问题。保持日常运营与计划之间的有效平衡

由于预算限制、人力短缺和时间限制，维护可能具有挑战性。

许多行业对维护活动都有严格的监管要求，以确保安全并符合行业标准。满足这些合规性要求给维护计划和安排增加了额外的复杂性，因为维护活动需要仔细记录并根据法规执行。

跨团队和部门的协调

有效的沟通对于协调维护活动、确定工单优先级以及共享有关设备和设施的重要信息至关重要。

在许多组织中，不同的部门和团队各自为政，只专注于自己的目标和目的。这种孤立的方法可能会阻碍部门之间的沟通和协作，从而难以有效协调维护活动。

组织内的每个部门可能有自己的优先事项和目标，有时可能与其他部门的优先事项和目标发生冲突，尤其是当这些团队必须共享有限的资源时。这可能会造成紧张，并使协调努力和资源实现共同维护目标变得具有挑战性。

有效的跨职能培训可以让员工充分了解彼此的角色和职责，从而有助于改善团队和部门之间的协调。此外，实施计算机化维护管理系统（CMMS）或其他维护管理软件可以帮助简化维护团队和其他部门之间的沟通并改善协作。

劳动力管理

确保维护团队拥有适当的技能、培训和资源来有效地完成工作对于保持高水平的设备可靠性至关重要，但劳动力管理可能具有挑战性。  

维护团队通常由具有不同技能水平、经验和专业知识的技术人员组成。要管理一支多元化的团队，您需要良好的沟通、协调和监督，以确保每个人都朝着同一个目标努力。

故障或紧急情况可能会扰乱计划的维护计划，并需要快速调整员工队伍。在这种情况下，维护经理要高效且有效地管理资源可能具有挑战性。

寻找和留住合格的技术人员可能很困难，特别是在缺乏熟练劳动力的行业。随着技术的发展，组织必须确保技术人员具备技能并接受过培训，能够有效地执行任务。然而，培训既耗时又昂贵。招聘和培训问题可能导致人员不足和现有工作人员的工作量增加。全面的培训计划、定期绩效评估以及持续的支持和反馈可以改善劳动力管理并最大限度地提高维护团队的效率。提高现有员工的技能还可以确保技术人员掌握最新的技术

技术。我们将在下面更详细地讨论与技术进步相关的挑战。

跟上技术发展

跟上维护技术（例如预测性维护工具和管理软件）的进步需要投资和培训。但从长远来看，整合新技术可以提高效率并降低成本。

新的技术进步不断发展，使得维护经理很难跟上最新的工具和系统。此外，实施新技术（例如升级设备和软件）的成本对于某些组织来说可能过高。

如上所述，培训员工如何使用和维护新技术可能既耗时又昂贵。一些员工可能会抵制变革并抵制学习新系统，从而使新技术的采用进一步复杂化。

跟上维护管理技术的进步需要致力于持续培训和专业发展，以及愿意接受变革和适应新技术。

安全与合规性

确保维护活动符合相关安全标准和法规至关重要。这包括管理与维护工作相关的风险并确保设备满足安全要求。

组织必须遵守众多法规和标准，以确保维护操作的安全。这些法规可能很复杂并且不断变化。

许多维护工人（包括现有团队成员和新员工）可能没有接受足够的安全程序和合规要求培训。这可能会导致安全协议失效，并增加事故和违规风险。

此外，在紧迫的期限内完成任务并保持设备平稳运行的压力可能会导致安全程序或合规措施走捷径，从而增加发生事故和违反监管规定的风险。

在实施和维护安全计划时，组织可能面临预算限制和资源限制。这使得投资必要的安全设备、培训和合规措施变得具有挑战性。

环境问题

维护活动通常涉及使用危险材料、化学品和设备，如果管理和处置不当，可能会对环境产生不利影响。平衡环境问题与维护需求需要仔细规划并遵守环境法规。

Maintenance activities can result in the generation of waste materials such as oil, grease, and other pollutants that can contaminate soil, water, and air if not handled correctly. It can also increase the consumption of energy and resources, contributing to greenhouse gas emissions and overall environmental degradation.

Implementing sustainable practices in maintenance management, such as energy-efficient equipment and processes, as well as proper waste management practices, can help mitigate these environmental impacts.

Environmental regulations are constantly evolving and becoming increasingly stringent. Maintaining compliance with environmental laws requires continuous monitoring and updating of maintenance practices to ensure they meet the necessary standards.

How to Implement an Effective Maintenance Management Plan

Having an effective maintenance management plan in place is crucial for the success and efficiency of any organization. By properly maintaining equipment, machinery, and facilities, companies can minimize downtime, reduce costs, and maximize productivity.

Implementing an effective maintenance management plan involves strategic planning, resource allocation, and continuous improvement to ensure that equipment and facilities are maintained at optimal levels. Here’s a step-by-step approach to developing and implementing a successful maintenance management plan:

  1. Establish objectives. It’s important to establish clear objectives and goals before implementing a maintenance management plan. Determine what you want to achieve with a maintenance management plan, such as reducing downtime, improving equipment lifespan, or decreasing maintenance costs. Setting clear goals will help you guide and measure your plan’s success.
  2. Conduct a maintenance audit and assessment. Assess the current condition of your equipment and facilities to identify areas that need improvement. This can include reviewing maintenance logs, inspecting equipment, and analyzing maintenance costs. Understanding your assets’ current state will help you develop a targeted maintenance plan.
  3. Implement a maintenance strategy. Determine the best maintenance strategies for different equipment types and operational needs. Reactive maintenance, preventive maintenance, predictive maintenance, prescriptive maintenance, reliability-centered maintenance, and total productive maintenance are common strategies discussed earlier in this guide. A combination of strategies is often used to implement effective maintenance programs.
  4. Tag your equipment and other assets. Tagging your equipment and other assets with asset tags or barcode labels provides the foundation for effective maintenance management. CMMS Maintenance Management Asset Tags, for example, help identify assets and equipment, identify measurement points, and time/date stamp measurement activities. Facility Management Asset Tags and Labels are available in various materials, such as durable Metalphoto® and premium polyester, designed to withstand harsh environments while remaining readable throughout the lifespan of your assets. 
  5. Allocate resources. A maintenance management plan requires skilled personnel, appropriate tools, and a sufficient budget. It may be necessary to hire more staff, invest in technology, or reappropriate funds.
  6. Select and deploy a CMMS or other maintenance software. A maintenance management software solution is a worthwhile investment if your organization doesn’t already use one.
  7. Develop a preventive maintenance schedule. Establish detailed inspection and routine maintenance schedules. You can keep your maintenance management activities on track by using comprehensive maintenance management software.
  8. Train and educate employees. Ensure that employees are aware of their roles and responsibilities within the maintenance program. Train users on equipment operation, maintenance procedures, and safety protocols to prevent accidents and maintain equipment reliability.
  9. Maintain up-to-date safety and compliance protocols. Ensure that all maintenance procedures are compliant with industry standards and regulations. To ensure safe and effective maintenance management, check and update your safety and compliance processes and procedures regularly.  
  10. Continuously monitor and evaluate performance. You can evaluate the success of your maintenance management program using key performance indicators (KPIs) like downtime, maintenance costs, and equipment lifespan. Demonstrate your commitment to continuous improvement by encouraging feedback from maintenance staff and other stakeholders.
  11. Maintain thorough documentation. Detailed documentation is essential for auditing, compliance, and planning future maintenance activities. Record all maintenance activities, costs, outcomes, and improvements.

Maintenance Management Metrics &KPIs

Maintenance management metrics and key performance indicators (KPIs) help your organization track and measure the effectiveness of its maintenance operations. Maintainers can use these metrics to identify areas for improvement, optimize resource utilization, and maximize equipment lifespan.

First, let’s differentiate maintenance management metrics and maintenance management KPIs. While the terms are commonly used interchangeably, there are differences between the two:

The distinction can vary depending on the organization’s focus and the context in which the measure is used. The following KPIs provide valuable insights into the effectiveness of various aspects of your maintenance program.

Mean Time To Repair (MTTR)

Mean Time To Repair is a KPI used in maintenance management to measure the average time it takes to repair an asset or piece of equipment after a failure.

To calculate MTTR, the total downtime for a specific asset or equipment is divided by the total number of repairs conducted during a specific time period. The formula for MTTR is:

MTTR =Total Downtime / Total Number of Repairs

For example, if a machine experiences a total downtime of 10 hours due to a failure and requires 2 repairs during that time, the MTTR would be calculated as:

MTTR =10 hours / 2 repairs =5 hours

A lower MTTR indicates that maintenance teams are efficient in identifying and resolving equipment failures, leading to quicker repairs and reduced downtime. On the other hand, a high MTTR may indicate inefficiencies in maintenance procedures, lack of resources, or equipment reliability issues that need to be addressed.

Mean Time Between Failures (MTBF)

MTBF is a measure of the average time between failures of a piece of equipment or a system. It is an important indicator of equipment reliability and can help maintenance managers make informed decisions about maintenance schedules and equipment replacement.

MTBF helps to identify equipment that may be prone to failures, enabling maintenance teams to take proactive measures to prevent downtime and reduce maintenance costs. By tracking MTBF over time, managers can also assess the effectiveness of maintenance strategies and make adjustments as needed.

By understanding how long a piece of equipment typically goes between failures, managers can schedule maintenance tasks accordingly. For example, if a piece of equipment has an MTBF of 500 hours, maintenance tasks can be scheduled at regular intervals before the equipment is expected to fail.

To calculate MTBF, divide the total amount of time that a piece of equipment is operational by the number of failures that have occurred:

MTBF =(Time Asset Has Been In Use – Unplanned Downtime Due to Breakdown) / Total Number of Breakdowns

The result is the average time between failures. For example, if a piece of equipment has been operational for 1,000 hours and has experienced 10 failures, the MTBF would be 100 hours.

Preventive Maintenance Compliance (PMC)

Preventive Maintenance Compliance measures the percentage of scheduled preventive maintenance tasks that have been completed on time. It provides valuable insights into how well the plan you’ve established is being followed.

Most organizations aim for a PMC of 90% or greater. To calculate PMC, use the following equation:

PMC =(Number of Executed Tasks / Number of Planned Tasks) x 100

Maintenance Backlog

This metric is used to track the maintenance work that has been identified and/or scheduled but hasn’t yet been completed. These tasks can include repairs, inspections, replacements, and other maintenance activities. It includes all types of maintenance (preventive, predictive, prescriptive, and corrective).

Quantifying your maintenance backlog requires identifying open work orders, estimating the time required to complete all tasks, and converting it into a measure of time that’s relevant to your organization.

For example, if your maintenance team can complete 100 hours of work per week and you have 400 hours in your backlog, your backlog is equivalent to four weeks of work. The maintenance backlog can be reported as:

Unplanned Machine Downtime

Unplanned machine downtime is a measure of the amount of time an asset is out of operation due to an unexpected problem or breakdown. Unplanned downtime can significantly impact production, increase maintenance costs, and disrupt supply chains.

In contrast, planned downtime occurs during scheduled maintenance, upgrades, or other predictable disruptions that are part of regular operations.

To calculate unplanned machine downtime, log instances when a machine stops operating unexpectedly, including any stoppage that was not scheduled. Record the length of time the machine remained non-operational (from the time the machine stopped to the time it returns to normal operation).

Add these times to determine the total duration of unplanned downtime events over a specific period, such as daily, weekly, or monthly. You may also want to consider the lost production volume or other financial costs associated with downtime using one of the following equations:

Total Downtime x Production Rate (Units Per Hour)

Or

Total Downtime x Average Revenue Per Unit of Production Time

Unplanned downtime can be measured for individual machines, groups of machines, or for all an organization’s equipment assets. 

Maintenance Cost as a Percent of Estimated Replacement Value (MC/ERV)

Maintenance costs as a percentage of the estimated replacement value of an asset provides a benchmark to determine if the amount being spent on maintenance is reasonable relative to the asset’s value.

A higher percentage might indicate excessive maintenance costs, possibly due to aging equipment requiring more frequent repairs. On the other hand, a lower percentage might suggest underinvestment in maintenance, which could lead to increased failure rates and operational risks.

To calculate this metric, you need the following figures:

Then, use the following formula:

Maintenance Cost as a % of ERV =(Total Maintenance Costs / Estimated Replacement Value) x 100

This is also called Maintenance Cost as a Percentage of Replacement Asset Value (RAV).

This ratio helps organizations understand how much they are investing in maintaining an asset compared to the cost of purchasing a new one, providing insight into the economic efficiency of their maintenance strategies.

Cost To Repair vs. Cost To Replace

Another approach to determining whether it makes sense to repair or replace an asset is to simply compare the cost to repair to the cost to replace an asset. The cost to repair is the expected annual cost of maintenance on the existing equipment. To determine the cost to replace, use the following formula:

Cost To Replace =(Cost of Replacement / Replacement Asset’s Lifetime) + Expected Annual Cost of Maintenance

For example,

Imagine you have an industrial machine with annual maintenance costs of $500. A new machine costs $8,000 and is expected to last 10 years, with annual maintenance costs of $300.

Cost to Repair (annually) =$500

Cost to Replace (annually) =($8,000 / 10 years) + $300

Cost to Replace (annually) =$800 + $300 =$1,100

In this scenario, the annual cost to replace the machine, $1,100, is higher than the annual cost to repair the existing one, $500. Despite the higher upfront cost of replacement, in this case, it might not make financial sense to replace the machine if the goal is to minimize annual expenditures.

However, the decision might differ if other factors such as improved efficiency, lower energy consumption, or critical reliability issues of the old machine are considered.

Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness (OEE) is a comprehensive metric used in manufacturing to measure the effectiveness of a production process. It identifies the percentage of manufacturing time that is truly productive.

An OEE score of 100% means you’re manufacturing only high-quality parts, as fast as possible, with no stop time. The ideal OEE score is considered to be 85%.

OEE provides a single number that reflects the effectiveness of your equipment and processes by combining three different factors:Availability, Performance, and Quality.

Availability =Operating Time / Planned Production Time

Performance =Total Count of Products / (Operating Time x Ideal Cycle Time)

Quality =Good Count / Total Count

To calculate the Overall Equipment Effectiveness metric, multiply these three factors:

OEE =Availability x Performance x Quality

Scheduled Maintenance Critical Percent (SMCP)

SMCP indicates how much scheduled maintenance work is critical to prevent operational disruptions and ensure safety. A high SMCP suggests that a significant portion of the maintenance schedule is vital for the functioning of the organization, which may indicate high reliance on certain equipment or systems.

A maintenance task is typically considered critical if delaying it or failing to perform it could lead to severe operational disruption, safety incidents, or significant financial loss. Monitoring SMCP helps in managing risks associated with equipment failure and optimizing the allocation of maintenance resources.

To calculate SMCP, use the following formula:

SMCP =(Number of Critical Maintenance Tasks / Total Number of Scheduled Maintenance Tasks) x 100

Asset Utilization Rate

Asset Utilization Rate measures the efficiency with which a business uses its assets to generate revenue. It indicates the percentage of time that assets are actually in use compared to the time they are available for use.

High asset utilization rates typically suggest that a company is effectively using its assets to produce goods or services. Lower rates, on the other hand, may indicate underused resources or inefficiencies in the production process.

To calculate the Asset Utilization Rate, use the following formula:

Asset Utilization Rate =(Actual Operating Time / Available Operating Time) x 100

Safety Incidents Rate

The Safety Incidents Rate is a crucial metric used in workplace health and safety management to quantify the frequency of accidents or safety incidents within a given period, typically in relation to the number of hours worked. It provides insights into the overall safety performance of an organization and helps to identify areas where safety improvements are needed.

When calculating the Safety Incidents Rate, it’s important to use a standardized measure to compare the rate over time and across organizations. Typically, the Safety Incidents Rate is calculated per 100,000 hours worked. To calculate it, use the following formula:

Safety Incidents Rate =(Number of Safety Incidents / Total Hours Worked) x 100,000

Maintenance Cost Per Unit

Maintenance Cost Per Unit measures the cost associated with maintaining equipment or other assets relative to the number of units produced. It provides valuable insights into the efficiency of maintenance expenditures and helps organizations optimize their production costs.

To calculate Maintenance Cost Per Unit, use the following formula:

Maintenance Cost Per Unit =Total Maintenance Costs / Total Units Produced

Distribution by Types of Maintenance Performed

Distribution by Types of Maintenance Performed is a metric used in maintenance management to classify and report the various types of maintenance activities performed over a specific period. This classification helps organizations understand how their maintenance efforts are allocated across different strategies, such as preventive, predictive, corrective, and condition-based maintenance.

By analyzing the distribution of maintenance types, companies can better manage their maintenance resources, improve planning, and potentially increase the overall reliability and efficiency of their equipment.

To calculate the Distributioni by Types of Maintenance Performed, record all maintenance activities performed during the reporting period, and classify them by type. Then add all recorded maintenance activities.

Then, use the following formula for each type of maintenance to determine the percent of maintenance activities of each type performed during the reporting period:

Percent of [Type] Maintenance =(Number of [Type] Maintenance Activities Performed / Total Number of Maintenance Activities) x 100 

Work Order Cycle Time

Work Order Cycle Time is a measurement of the time it takes to complete a maintenance work order from the moment it’s created until it’s closed. It’s an important metric for evaluating the efficiency of maintenance operations and the responsiveness of the maintenance team.

Lower cycle times generally indicate a more efficient process, which can lead to higher equipment availability and reliability. Higher cycle times can indicate bottlenecks or a shortage of labor or other resources.

The formula to calculate Work Order Cycle Time is simple:

Work Order Cycle Time =End Time – Start Time

To get a broader view of your maintenance efficiency, calculate the average cycle time across multiple work orders over a specified period. You might also want to analyze cycle times by type of maintenance, criticality of equipment, or team/technician to identify patterns or areas for improvement.

Inventory Turnover Ratio

Inventory Turnover Ratio is a measure indicating the frequency with which maintenance inventory (e.g., spare parts, supplies) is used and replenished within a given period. It helps organizations understand how effectively they’re managing the inventory that supports its maintenance operations.

Maintaining maintenance inventory efficiently can help reduce carrying costs, minimize obsolescence waste, and ensure the availability of critical parts when needed, preventing excessive downtime.

To calculate Inventory Turnover Ratio, you need two figures:

Average Maintenance Inventory =(Beginning Inventory + Ending Inventory) / 2

Once you have these figures, calculate the Inventory Turnover Ratio using the following formula:

Inventory Turnover Ratio =MRO Expenditure / Average Maintenance Inventory

Overtime

In maintenance management, overtime is a valuable metric that can help organizations understand the efficiency and effectiveness of their maintenance operations. High levels of overtime can indicate problems such as insufficient staffing, unexpected equipment failures, or inefficient work processes, all of which can increase operational costs and affect overall productivity.

To calculate Overtime, use the following formula:

Overtime Hours =Actual Hours Worked – Standard Hours

Overtime can be calculated by employee, department, or the organization as a whole. 

It’s also useful to analyze overtime data over different periods (weekly, monthly, yearly) to identify trends and patterns. This analysis can help in forecasting future staffing needs and adjusting work schedules to optimize resource utilization.

Maintenance Management Technologies &Software Trends

Maintenance management software enables organizations to streamline maintenance operations, prioritize tasks, and make data-driven decisions to optimize asset performance.

Many modern maintenance management software solutions allow managers to easily calculate, monitor, and report on the KPIs discussed in the previous section.

Research indicates that more organizations are embracing digitalization and adopting technologies and software to streamline and optimize maintenance management.

Based on data from Plant Engineering

Plant Engineering surveyed plant engineers, managers and maintenance professionals on the purchase and use of maintenance management systems in its 2022 Purchasing Considerations for Maintenance Management Software report. According to the report, most respondents use CMMS or EAM software in their facilities:

Based on data from Plant Engineering

In an earlier report from 2021, Plant Engineering found that while 54% of plants reported using CMMS and 16% reported using EAM software at the time of the survey, a surprising number of plants relied on more basic systems and tools to monitor or manage maintenance:

However, facilities are also employing more advanced maintenance management tools. In addition to the above, 44% of respondents reported using an automated maintenance schedule, 16% reported using EAM, and 8% reported using Industrial IoT, SaaS, or cloud computing systems.

Types of Maintenance Management Software

There are several types of maintenance management software that help organizations effectively manage their assets and equipment, each with unique features and capabilities.

Let’s take a closer look at the most common types of maintenance management software and how they support maintenance operations.

Computerized Maintenance Management Software (CMMS)

Computerized Maintenance Management Software (CMMS) is the most traditional form of maintenance management software. It’s widely used in industries such as manufacturing, healthcare, facilities management, and transportation, among others.

CMMS solutions help organizations organize and track maintenance activities more effectively, reducing downtime, increasing equipment lifespan, and reducing costs. It allows maintenance managers to create and assign work orders, track inventory and spare parts, and generate reports on maintenance performance.

Key capabilities of CMMS include:

Enterprise Asset Management (EAM) Software

EAM software helps organizations manage the lifecycle of their physical assets across various departments, locations, and facilities. Unlike simpler systems such as Computerized Maintenance Management Systems (CMMS), which focus primarily on maintenance scheduling and tracking, EAM provides broader functionalities that cover the entire range of asset management activities.

The primary goal of enterprise asset management software is to maximize the lifespan and value of assets while minimizing costs and downtime. It helps businesses keep track of their assets, schedule maintenance and repairs, manage inventory, and analyze data to make informed decisions about asset usage and resource allocation.

Key capabilities of EAM include:

Facility Management Software

Facility management software encompasses a wide range of functionalities that help facility managers ensure that their buildings are operating efficiently, safely, and cost-effectively.

It helps organizations reduce costs through efficient space utilization, energy management, and preventive maintenance, minimizing energy costs and reducing the need for costly repairs.

Key capabilities of facility management software include:

Predictive Maintenance (PdM) Software

Predictive maintenance (PdM) software uses advanced analytics and machine learning algorithms to predict when equipment failures are likely to occur. By analyzing data from sensors and other sources in real-time, PdM software can help organizations proactively maintain and repair their machinery before it breaks down, saving time and money in the long run.

PdM software also enables companies to optimize their maintenance schedules by identifying trends and pattenrs in equipment performance through historical data analysis and real-time condition monitoring. 

Key capabilities of PdM software include:

Reliability-Centered Maintenance (RCM) Software

Reliability-Centered Maintenance (RCM) software is tailored specifically to support the reliability centered maintenance methodology. This software helps organizations understand the potential causes of asset failure and prioritize maintenance based on safety, operational, and economic consequences, allowing organizations to allocate resources more effectively. 

RCM integrates with sensors and monitoring systems to track asset performance and conditions in real-time and suggests the most appropriate maintenance tasks based on the asset’s risks and failure modes. By focusing on the maintenance activities that have the most impact on reliability and safety, RCM helps to avoid unnecessary maintenance activities, thus reducing maintenance costs.

RCM can be integrated with other software solutions for a more comprehensive approach to maintenance management.

Key capabilities of RCM include:

Maintenance Scheduling Software

Maintenance scheduling software is a type of application specifically designed to assist organizations in planning, coordinating, and tracking maintenance activities to ensure they are completed efficiently and on time. It plays a crucial role in both minimizing equipment downtime and maximizing productivity by ensuring that all maintenance tasks are systematically organized and executed according to a set schedule.

Maintenance scheduling software automatically schedules maintenance tasks based on preset intervals, usage metrics, or condition-monitoring data. It can integrate data from preventive and predictive maintenance strategies to optimize the timing and scope of scheduled maintenance activities. This software also helps to optimize resource allocation to ensure that all tasks are covered without overloading resources.

Key capabilities of maintenance scheduling software include:

Asset Performance Management (APM) Software

Asset performance management software is designed to optimize the performance, reliability, and availability of physical assets throughout their lifecycle. This type of software helps organizations monitor and manage the health of their equipment and infrastructure to reduce downtime, increase longevity, and improve overall operational efficiency.

APM enables organizations to shift from costly reactive maintenance strategies to more cost-effective predictive and reliability-centered maintenance approaches. It provides comprehensive data and analytics that enables organizations to make informed decisions related to their asset management strategies.

Key capabilities of APM include:

The Role of a Maintenance Manager

A maintenance manager fulfills a vital role between a maintenance director or another top-level executive and the supervisors and technicians who perform the bulk of the service work. The role requires a unique mix of technical skills and business acumen to see the big picture while also addressing day-to-day issues and needs.

Given the complexities of maintenance work activities that take place at many companies, the job responsibilities of a maintenance manager can cover a broad scope. Some of the significant areas of focus include:

A maintenance manager can wear many hats, and there are some similarities with the responsibilities of a facilities manager or asset manager. As a leadership position, many technical and soft skills are also desired in a maintenance manager. Some of the most sought-after skills are:

A maintenance manager must balance a company’s performance goals with the realities of equipment capabilities. In highly specialized industries that serve a large number of customers, such as aerospace and healthcare, the stakes are even higher. This is the main reason why a good balance between soft skills and technical knowledge is required to be an effective maintenance manager.

It’s only with close cross-departmental collaboration that companies can create a robust maintenance management program. Maintenance work should never take place in a vacuum, and it’s vital for managers to solicit feedback from technicians, operators, and other staff that interact with equipment.

Maintenance Management Trends

Current trends in maintenance management are largely centered on technology. As more sophisticated technologies become available, a growing number of organizations are embracing these tools to optimize asset performance and extend the useful lifespan of equipment while minimizing maintenance costs.

Here’s a closer look at the current trends in maintenance management.

Increased Adoption of Predictive and Condition-Based Maintenance

As maintenance becomes more data-driven, facilities are increasingly adopting smart sensors that monitor conditions in real-time to preemptively address potential issues. This involves tracking vibrations, temperatures, and other indicators to predict and prevent equipment failures​.

Along with this, predictive maintenance continues to gain popularity. Predictive maintenance, as described previously, is a shift from corrective maintenance and even goes beyond preventive maintenance.

Rather than waiting for equipment to fail and dealing with the consequences of unplanned downtime, predictive maintenance uses sensors and monitoring systems to analyze equipment performance and predict when maintenance is needed. There’s a growing adoption of techniques that range from basic anomaly detection to sophisticated models predicting the remaining useful life (RUL) of machinery.

Use of Immersive Technologies

Augmented reality (AR) and virtual reality (VR) are being utilized to enhance training and maintenance procedures. AR can significantly reduce errors and increase efficiency by providing real-time, on-the-job guidance. Technicians receive overlay visual prompts and step-by-step instructions while they work, which helps in reducing guesswork and streamlining complex tasks.

It can also help reduce the costs associated with traditional training methods, such as creating physical mock-ups or taking equipment offline for training purposes. This provides a safe and controlled environment where maintenance personnel can learn and practice skills without the risk of damaging equipment or causing operational downtime. 

Additionally, training in a virtual environment allows maintenance personnel to experience and react to potential hazardous situations in a controlled and risk-free setting. This better prepares them for real-world scenarios, enhancing overall safety.

Digital Twins

A related trend to immersive technologies, digital twins are virtual models designed to accurately reflect a physical object, system, or process. They’re used to simulate, predict, and optimize the performance and maintenance of physical assets through real-time data updates and analytics. This technology enables detailed analysis and testing without the risks and costs associated with manipulating the actual assets.

Digital twins support predictive maintenance by simulating how equipment will perform under various conditions and predicting when it might fail. Organizations can also simulate different maintenance scenarios to find the most cost-effective approach without having to experiment on the actual equipment.

Simulating equipment performance in a virtual environment allows potential issues to be identified and resolved before they become hazardous in the real world. This significantly enhances safety for both the equipment and the operators.

Integration of Maintenance Management with Other Business Processes

Organizations are increasingly taking a more holistic approach to maintenance management, integrating maintenance with other business practices, such as supply chain management, production planning, and human resources.

This integration allows for smoother operations across departments. For example, linking maintenance data with ERP systems can streamline the procurement of spare parts and inventory management, reducing downtime and operational delays.

By having maintenance data feed into broader business analytics, organizations can gain more comprehensive insights into how maintenance activities impact overall business performance. This holistic view supports better strategic decision-making and helps in prioritizing maintenance tasks based on their impact on business operations.

Additionally, linking maintenance management with production systems allows for real-time adjustments in production planning based on the current status of equipment. This helps maximize asset utilization and minimizes disruptions due to equipment failures.

Remote Equipment Monitoring

Remote equipment monitoring refers to the use of sensors and network technology, such as IoT devices, to track the performance and condition of machinery from a distance. This technology collects data such as temperature, vibration, and output levels, which is then transmitted to centralized systems where it can be monitored and analyzed in real time.

Monitoring equipment remotely reduces the need for physical inspections, which can be costly, time-consuming, and sometimes hazardous. This can significantly cut down travel and labor costs, especially for businesses operating over large geographic areas or difficult-to-access locations.

It also allows companies to identify potential safety hazards before they pose a risk to operations or personnel, enhancing workplace safety and aiding in compliance with regulatory standards.

Remote equipment monitoring is part of a broader shift towards smarter, more connected industrial operations known as the Industrial Internet of Things (IIoT). As technology continues to advance, the adoption of remote monitoring is expected to increase, driving efficiencies and competitive advantage in maintenance management across various industries.

Robotics and Automation

Robots and automated systems can operate continuously and perform tasks with precision that might be difficult to achieve manually. This leads to improvements in the quality of maintenance work and reduces human error, thereby increasing the overall reliability of equipment.

Robots can also access areas that are difficult or unsafe for humans, ensuring that maintenance can be performed without compromising safety. Although the initial investment in robotics may be high, over time, they can reduce labor costs and minimize costly downtime by ensuring maintenance is done promptly, correctly, and safely.

Additionally, these systems can be scaled up or down based on the needs of the business. As operations expand, additional robots can be seamlessly integrated into the maintenance routines without the need for extensive training that would be necessary for human workers.

3D Printing for On-Demand Parts

The trend towards using 3D printing for on-demand parts in maintenance management is driven by its potential to enhance operational efficiency, reduce costs, and improve service response times. It enables the production of parts only when needed, significantly reducing the need for large inventories of spare parts. This not only saves on storage space but also reduces capital tied up in stock that might become obsolete.

Plus, the ability to print parts on-site or nearby reduces the waiting time associated with ordering and shipping replacement parts from suppliers. This rapid response capability is crucial for industries where downtime is extremely costly.

3D printing also allows for the customization of parts to meet specific requirements without the need for costly retooling. It also supports the maintenance of older equipment where original parts may no longer be available from manufacturers.

As 3D printing technology continues to advance, its adoption is expected to grow, establishing it as a critical tool in modern maintenance strategies.

Collaboration and Knowledge Management

Collaboration and knowledge management in maintenance management involve the systematic sharing and organization of information, expertise, and communication across various levels of an organization. This strategy ensures that valuable maintenance insights and operational knowledge are not only shared but also retained within the organization.

Digital tools and platforms help to facilitate the sharing of documents, maintenance schedules, real-time data, and best practices among team members. By facilitating smooth communication and collaboration across different departments and teams, organizations can avoid the silos that often slow down response times and create inefficiencies in handling equipment maintenance.

Sharing knowledge widely also helps in standardizing practices and upskilling the workforce. New employees can learn from documented experiences and expertise, improving the overall skill level within the maintenance team.

Additionally, by having a robust system where issues and their resolutions are recorded and shared, the maintenance team can avoid reinventing the solution wheel. This leads to quicker fixes for common problems and reduces the time and resources spent on repeat issues.

A collaborative and well-informed workforce can also pivot more effectively to meet changing operational demands. In rapidly changing industrial environments, the ability to adapt and respond to new challenges is crucial.

常见问题


工业技术

  • 制造工艺
  • 3D打印
  • 自动化控制系统
  • 工业技术

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