I’ve worked in the plant maintenance industry for years. How did KPI’s look in those days? Here is an example KPI in 1988: “Keep the machines running”.
Fresh out of engineering school and thrown into the corporate engine, my life was all about keeping the conveyor belts running. That was the priority (and still is, but said differently) at United Parcel Service so that little Jimmy would get his red wagon in time for Christmas. Although we had no clue that they had a name (KPIs), here was our mission during the UPS days:
- Keep the belts running
- Get your PM’s done
- Anything stopped for 15 minutes was a breakdown
- Make sure mechanics knew how to make a repair the UPS way
- That is..because every action that a mechanic took was measured using a DOS program built by UPS (called PEMMS)
Now UPS was way ahead of their time with work measurement, starting, of course, among the fleet delivery drivers. They moved that successful approach to every aspect of the business, including maintenance.
Now the world is catching up to such great role models like UPS. However, the aspect of defining KPI’s has still been somewhat behind the curve. KPIs can be a mystery unless you happen to be a maintenance professional with enough hours available in the day for reading all the great maintenance measurement books available. Show me one of those people and I will immediately tell you that that person is a consultant. (No offense to the great consultants. I am guilty as charged)
Once again the Internet is bailing us out by saving a ton of time and making KPI definitions easier to grasp and define (without having to read a novel then construct a maintenance business plan, etc).
Here is example KPI where you can see the industry baseline then work your own numbers by taking a survey: Preventative maintenance hours as a percentage of total maintenance hours
As our training staff combs through North America teaching folks how to use MP2 CMMS Software I can’t help but notice a pattern of success we are teaching that I feel will benefit folks using any type of CMMS Software.
The advice I have to share is succinctly stated in the title of this post: Take Small CMMS Bites. And that means don’t try to pull off a CMMS project where everything is included at the outset.
In fact, make a small manageable plan, such as scoping out the entry of all PM’s into the CMMS system using your equipment manuals. Identify the equipment, locate the manuals, identify your resources for data entry, THEN cut all that way down again. Instead of entering PM’s for ALL your equipment, just choose 5 pieces of equipment for your first go-round. Take all your air compressors, for example, plus two HVAC units, and enter the PM details as recommended by the manufacturer of each.
The result will be a manageable scope of work whereby you will identify all the hurdles on a smaller scale, find solutions to get past those hurdles, and find your team succeeding at this first…small…bite, before taking the next.
I do quite a bit of training on MP2 CMMS across North America. As I visit sites and work with maintenance teams, there are some similaritieis worth sharing. Regardless of whether the maintenance business I am working with is tasked to maintain assets within either Manufacturing or Facilities, the underlying challenges remain similar.
My point today is to stress that maintenance improvements can be realized WAY before CMMS is installed and configured. In fact, without some diligent planning before a CMMS is purchased and implemented, there is a pretty good chance you won’t have a clue HOW to configure the CMMS system you just dropped hard-earned budget dollars into.
Here are some simple steps to maintenance improvements (at a high level):
- Define current maintenance processes
- Brainstorm ideas on how to improve current maintenance processes
- Draw up a plan for future maintenance processes
- Evaluate and purchase a CMMS that will serve as a tool with all the bells and whistles required to meet your future maintenance processes
- Configure the new CMMS to match your new maintenance processes
- Set a timetable to transition into the new maintenance processes
These steps are simplified and presented at a high level to highlight my point that CMMS is only part of the required process.
If you would like to learn more, please feel free to visit us at www.mp2training.com