A Comprehensive Guide to the Most Commonly Used Metrics and Efficient Tracking Methods

 If you’re responsible for maintaining equipment, you know how important it is to keep them running smoothly and avoid costly downtime. One key to achieving this is by tracking and analyzing common maintenance metrics. By doing so, you can gain insights into the health of your equipment and identify areas for improvement, and optimize your maintenance program.



From the report “The True Cost of Downtime,” large facilities experience an average of 27 hours of machine failures per month, resulting in a cost of $532,000 for each hour of unplanned downtime. This is worth US$864 billion per year across Fortune Global 500 industrial companies. Usually, the cause of such failures is the absence of knowledge about the right metrics, let alone the process to track them.

With the right metrics at their disposal, companies can establish robust performance benchmarks and prioritize improvement, strategy, and long-term growth. This entails identifying improvement areas, aligning KPIs with overall business strategy, and a strong monitoring process.

Overall, by tracking maintenance metrics, you can remarkably improve the outcome from your equipment. As a result, here, in this blog post, we’ll explore some of the most common maintenance metrics and tips on how to track them effectively.

Exploring Essential Metrics for Effective Maintenance Management

A holistic equipment maintenance and management strategy has a backing of relevant metrics and a strong monitoring system. Here, we first start by exploring the common metrics that are used to improve and optimize maintenance operations.

Mean time to repair (MTTR)

MTTR is the measurement of the average time taken to fix a piece of equipment or machinery after it has malfunctioned. It’s like a stopwatch that ticks from the moment a machine fails to the point it is back in working condition.

MTTR= total repair time / total number of repairs

It is an essential measure of maintenance efficiency, and a low MTTR indicates that the maintenance team can quickly identify and resolve equipment failures. This means less downtime and more time for production. In contrast, a high MTTR indicates that maintenance processes may not be effective, leading to increased downtime and reduced productivity.

By tracking MTTR, organizations can pinpoint the root cause of equipment failure and take necessary steps to prevent similar failures in the future.

Emergency work orders (EWOs)

EWO is an unplanned or emergency maintenance task that requires immediate attention to prevent further damage or safety hazards. EWOs are a critical measure of maintenance team responsiveness and agility.

It is calculated by,

EWOs = Total emergency work orders / Total number of work orders

When an EWO is raised, it’s a race against the clock to get the equipment up and running as quickly as possible. Tracking EWOs helps organizations identify recurring issues and evaluate the effectiveness of their maintenance processes. A high number of EWOs is an indication of poor equipment reliability or a lack of preventive maintenance.

Planned maintenance percentage (PMP)

Planned maintenance percentage is a measure of the percentage of maintenance tasks that are planned and scheduled in advance. It’s like a forecast for maintenance work that needs to be carried out in the future, ensuring that everything is in order before it becomes a problem.

PMP = Planned maintenance hours / Total maintenance hours × 100

Tracking PMP enables maintenance teams to identify areas for improvement and optimize their maintenance processes further. For example, if PMP is low, maintenance teams may need to adopt more preventive maintenance measures or should improve scheduling practices. PMP values over 90% are described as world-class maintenance, whereas values over 70% are acceptable.

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