Measuring Percentage Planned vs Emergency Maintenance

Maintenance work orders are a critical aspect of any manufacturing operation. They ensure that equipment is kept in optimal condition, reducing downtime and increasing productivity. However, striking a balance between planned and emergency maintenance work orders can be a challenge. This article will guide you on how to measure the percentage of planned vs emergency maintenance work orders in a manufacturing context.

Understanding Maintenance Work Orders

Maintenance work orders are formal requests that initiate the process of repairing or maintaining a piece of equipment. They are typically divided into two categories: planned and emergency (or unplanned) maintenance work orders. Understanding the difference between these two types of work orders is crucial in managing a manufacturing operation effectively.

Planned maintenance work orders are scheduled in advance and are part of a preventive maintenance strategy. They aim to keep equipment in good working condition and prevent unexpected breakdowns. On the other hand, emergency maintenance work orders are reactive, initiated when a piece of equipment breaks down unexpectedly. These types of work orders can disrupt production schedules and lead to increased costs.

Importance of Measuring Planned vs Emergency Maintenance Work Orders

Measuring the percentage of planned vs emergency maintenance work orders is an essential part of maintenance management. This metric provides insights into the effectiveness of your preventive maintenance strategy and the overall health of your manufacturing operation.

A high percentage of planned maintenance work orders indicates a proactive approach to maintenance, potentially leading to fewer equipment breakdowns and lower maintenance costs. Conversely, a high percentage of emergency maintenance work orders may suggest that your preventive maintenance strategy is not effective, leading to more frequent equipment failures and higher maintenance costs.

How to Measure Percentage Planned vs Emergency Maintenance Work Orders

Measuring the percentage of planned vs emergency maintenance work orders is a straightforward process. The formula is as follows:

Percentage planned vs. emergency maintenance work orders = (# of planned maintenance hours / # of unplanned maintenance hours) × 100

By using this formula, you can calculate the ratio of planned to emergency maintenance work orders, expressed as a percentage. This will give you a clear picture of how your maintenance efforts are divided and help you identify areas where improvements can be made.

It's important to note that this measurement should be used as a guide rather than a hard and fast rule. Different manufacturing operations have different needs and circumstances, so what constitutes a "good" percentage may vary.

Improving the Balance Between Planned and Emergency Maintenance Work Orders

Once you've measured the percentage of planned vs emergency maintenance work orders, you can take steps to improve this balance. This typically involves enhancing your preventive maintenance strategy to reduce the number of emergency work orders.

One effective approach is to implement a condition-based maintenance strategy. This involves monitoring the condition of equipment and performing maintenance when certain thresholds are reached. This can help prevent unexpected breakdowns and reduce the need for emergency work orders.

Another strategy is to invest in maintenance training for your staff. Well-trained staff are more likely to spot potential issues before they become serious problems, reducing the need for emergency work orders.

Conclusion

Measuring the percentage of planned vs emergency maintenance work orders is a valuable tool for any manufacturing operation. It provides insights into the effectiveness of your maintenance strategy and can help you identify areas for improvement. By striving for a balance between planned and emergency work orders, you can reduce downtime, increase productivity, and ultimately improve your bottom line.