Understanding Maintenance KPIs: A Guide to Enhancing Your Operations with Gemini Smart

Understanding Maintenance KPIs: A Guide to Enhancing Your Operations with Gemini Smart

Companies have talked about key performance indicators (KPIs) for years. Everyone understands that having a firm grasp on the best KPIs for your organization means reducing downtime and boosting revenue. Yet, in the real world, when critical equipment requires reactive maintenance on a regular basis, it’s hard to prioritize setting up KPIs and strive for world-class standards.

Understanding exactly what KPIs are and how to tie them to overall business objectives can help. Here are some tips on selecting the best ones for your organization and how to track them more easily so that you can reap the benefits, thanks to advanced tools like Gemini Smart.

What is a Maintenance KPI?

A KPI measures the performance of specific tasks, processes, groups, or team members. Maintenance KPIs that are well-selected to be met within a particular time frame can help organizations boost production, decrease costs, improve safety, and gain efficiency. KPIs work hand-in-hand with metrics: metrics measure the steps toward a goal while the KPI is the goal itself.

Choose Your KPIs

Selecting the right KPIs for your organization can be difficult due to the sheer number of possibilities. Many can appear to be great goals to strive for, but if they don’t fit your company’s goals and strategy, they will not be the right choice for your business.

Ideally, you should select five or fewer KPIs for any given period. They need to be very focused on improvements, strategy, or long-term growth while supporting your company’s overall goals. Remember KPIs are not forever; they will change over time and as your company grows and matures.

Finally, don’t forget to obtain buy-in from your managers and leaders. Maintenance supervisors will be closer to the pressing problems at the technician and production level. C-suite executives need to solicit their feedback, understand their struggles, and listen to their suggestions before selecting the five KPIs. Gemini Smart can help you collect and analyze the data needed to make these decisions.

Top Ten Maintenance KPIs

While each company will be unique, many share commonalities in their overall goals of reducing repair times, boosting efficiency, and decreasing costs. Check out these top ten for inspiration in selecting your three to five KPIs:

1. Equipment Downtime You can create a KPI around equipment downtime in one of two ways. You can either try to reduce the amount of time your equipment is unavailable due to emergency breakdowns or work to increase how often a machine is doing what it’s supposed to do.
2. Maintenance Backlog By monitoring how many work orders exist in your system, you can determine appropriate staffing needs. Few or no work orders sitting in the backlog probably means you are overstaffed and could reassign some resources elsewhere. However, a high number of backlogged work orders may signal a need to hire more technicians. Gemini Smart offers real-time tracking tools that facilitate backlog management and resource allocation.
3. Mean Time Between Failure and Mean Time to Repair Mean Time Between Failure (MTBF) tracks the time between each equipment failure for one asset and then finds the average. Mean Time to Repair (MTR), on the other hand, looks at the period from the moment of failure to when the asset is back in working order. Gemini Smart automates the calculation of these KPIs and provides alerts in case of anomalies.
4. Overall Equipment Effectiveness Overall Equipment Effectiveness (OEE) tracks a company’s overall performance by examining asset availability, performance efficiency, and product quality.
5. Planned Maintenance Percentage (PMP) Planned Maintenance Percentage (PMP) measures how much of an organization’s total maintenance is planned. Planned maintenance is always less costly than emergency maintenance. Gemini Smart helps in planning and tracking maintenance activities, improving PMP.
6. Schedule Compliance Schedule compliance monitors the percentage of time that a company actually completes a scheduled work order. Best-in-class standards are 90 percent or greater for this KPI.
7. Maintenance Cost as Percent of Replacement Asset Value By measuring how cost-effective your maintenance program is, you can determine your maintenance cost as a percent of replacement asset value.
8. Average Days to Complete Work Orders Many companies may focus on how quickly work orders can be completed as a measure of efficiency. However, be sure you don’t end up sacrificing quality for speed.
9. Percentage of Work Covered by Work Order It’s important that maintenance work is recorded in a computer system to provide data for smart future decisions. This KPI tracks that, and the goal should always be 100 percent. Gemini Smart can help ensure full coverage of maintenance activities.
10. Maintenance Overtime While overtime may not be completely avoidable, you may be able to hold it to a best-in-class level of around 5 percent. Similar to the maintenance backlog KPI, this one can help you make solid labor decisions.

Tracking KPIs with Gemini Smart

Many technological solutions exist today to help companies track KPIs, but few offer the ease of use and advanced capabilities of Gemini Smart. This solution allows you to:

• Automate data collection and KPI calculation.
• Receive real-time notifications and alerts.
• Access detailed reports and advanced analytics.
• Customize KPIs according to your company’s specific needs.

Investing in an effective system like Gemini Smart will help you better understand resource costs, reduce unplanned downtime, and improve overall operational efficiency.

Whatever tool you select, be sure to frequently review your selected KPIs, updating or replacing them as your business needs evolve. With Gemini Smart, you can continuously monitor and optimize your KPIs, reaping all the benefits of effective maintenance management.