HSB Reliability Technologies

Industry Benchmark Survey

Industry Benchmark Survey

COMPANY NAME_______________________________PLANT/FACILITY NAME _________________________________

LOCATION

_______________________________LOCATION___________________________________________

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COMPANY REP._______________________________TELEPHONE NO.___________________ FAX ________________

World Class Maintenance( Benchmark Indicators

IndicatorIndicator DescriptionResponseComments

1What is the percent of annual total expense maintenance costs to annual total plant sales? Total maintenance costs include shutdown/turnaround annualized allocations.

2What is the percent of annual total maintenance costs to plant replacement asset value (RAV)? RAV is the cost of replacing current assets.World Class 1.5% TO 2.0%

3What is the percent of maintenance stock value to RAV?World Class 0.5%

4What is the RAV value per maintenance employee?World Class > $5,000,000

5What is the cost per employee based on annual total expense maintenance cost?World Class > $100,000

6What is the number of maintenance craft personnel per first line supervisor (company and contract)?World Class - 15 to 20

7What is the number of maintenance craft personnel per planner?World Class 30 to 60

8What is the number of first line supervisors per planner?World Class 2 to 3

9How many organizational levels between plant manager and maintenance craft personnel?World Class 2 to 3

10What percent of critical performance measures have been achieved?World Class > 90%

IndicatorIndicator DescriptionResponseComments

11Training dollars represent what percent of the maintenance budget?World Class 4% to 5%

12What is the number of specific crafts used in routine maintenance?World Class 2 to 3

13What percent of minor maintenance work is accomplished by production?World Class 30% to 40%

14What percent of equipment have Preventive Maintenance (PM) tasks been developed for and used?World Class 80%

15In maintenance, how many hours is each craft person scheduled?World Class 8 of 8 hrs or 100%

16What is the percent of completed work orders that have been planned?World Class > 95%

17What is the percent of completed work orders that are PM?World Class 30 to 60

18What percent of systems have had a full Reliability Centered Maintenance analysis?World Class > 20%

19How many weeks of backlog for the total maintenance crew?World Class 2 to 3 weeks

20What is the percent of completed work orders that are emergency?World Class < 5%

21What is the percent of rework by maintenance?World Class < 5%

22What is the percent of overtime to total maintenance hours worked?World Class - 5% to 8%

23What is the percent for availability for production systems? (Use composite rate for multiple production systems).World Class 94%

24What are the annual inventory turns for maintenance material (annual issue dollars divided by average inventory dollars)?World Class 3 to 4 turns

25What is the percent of emergency purchase orders?World Class < 10%

26What is the percent of on-time delivery for purchased goods?World Class > 90%

27What is the percent of vendor stock to on-hand maintenance stores stock (by value)?World Class > 30%

28What is the percent of inventory accuracy of maintenance spare parts?World Class > 98%

29What is the percent of maintenance parts stockouts?World Class < 5%

30What percent of warehouse line items show no issue in the last three years?World Class < 10%

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