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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