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Best Practices Maintenance Benchmarks
| Category | Benchmark |
|---|---|
| Yearly Maintenance Cost: | |
| Total Maintenance Cost/Total Manufacturing Cost | < 10-15% |
| Maintenance Cost/Replacement Asset Value of the Plant and Equipment | < 3% |
| Hourly Maintenance Workers as a % of Total | 15% |
| Planned Maintenance: | |
| Planned Maintenance/Total Maintenance | > 85% |
| Planned & Scheduled Maintenance as a % of hours worked | ~ 85-95% |
| Unplanned Down Time | ~ 0% |
| Reactive Maintenance | < 15% |
| Run to Fail (Emergency + Non-Emergency) | < 10% |
| Maintenance Overtime: | |
| Maintenance Overtime/Total Company Overtime | < 5% |
| Monthly Maintenance Rework: | |
| Work Orders Reworked/Total Work Orders | ~ 0% |
| Inventory Turns: | |
| Turns Ration of Spare Parts | > 2-3 |
| Training: | |
| For at least 90% of workers, hours/year | > 80 hours/year |
| Spending on Worker Training (% of payroll) | ~ 4% |
| Safety Performance: | |
| OSHA Recordable Injuries per 200,000 labor hours | < 2 |
| Housekeeping | ~ 96% |
| Monthly Maintenance Strategies: | |
| Preventive Maintenance: Total Hours PM/Total Maintenance Hours Available | ~ 20% |
| Predictive Maintenance: Total Hours PdM/Total Maintenance Hours Available | ~ 50% |
| Planned Reactive Maintenance: Total Hours PRM/Total Maintenance Hours Available | ~ 20% |
| Reactive Emergency: Total REM/Total Maintenance Hours Available | ~ 2% |
| Reactive Non-Emergency: Total RNEM/Total Maintenance Hours Available | ~ 8% |
| Plant Availability: | |
| Available Time/ Maximum Available Time | > 97% |
| Contractors: | |
| Contractors Cost/Total Maintenance Cost | 35-64% |
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