Maintenance Metrics: What is Preventive Maintenance Compliance?

What is Preventive Maintenance Compliance?

Preventive Maintenance Compliance (PM Compliance) or Schedule Compliance is the rate of completion of Preventive Maintenance schedules.  Preventive Maintenance activities are set to recur at a specific interval.  So for any given period of time, there will be a number of preventive maintenance work orders generated for the various equipment available in the plant.  PM Compliance is a measure of completion of PM activities in the given period.

 

 

Why do we measure PM Compliance?

Preventive Maintenance activities are scheduled as a proactive maintenance of equipment and facilities, to avoid unplanned failures.  Thus, they increase the overall uptime and availability of the equipment.  Regular preventive maintenance increases the life of the equipment in the long run.  Being a planned activity, preventive maintenance also helps in scheduling the tasks in advance in such a way to cause least disruption to production schedule, thereby improving equipment efficiency and people productivity.

With numerous PM activities planned for the different equipment and each such preventive maintenance order having its own set of schedules and tasks, we need metrics to calculate the overall completion and adherence to the schedule.  PM Compliance gives an easy to calculate measure to track the PM completion status.

 

How do you calculate PM Compliance?

PM Compliance or Schedule Compliance is measured as the number of preventive maintenance activities completed to total number scheduled in a given period of time and is expressed as a percentage.

 

The formula used for calculating PM Compliance is

PM Compliance =  (Number of Work Orders Completed / Total Number of Work Orders) x 100

 

How do Enterprises use PM Compliance?

The different ways in which PM Compliance is calculated and used include

1.    Overall PM Compliance for a given period:   Calculates the total PM Compliance for all the assets under consideration for the given period.  For a manufacturing organization, it can be the overall completion rate for all the plants put together,

2.    PM Compliance for all the equipment in a given plant, unit or facility:  PM compliance can be calculated at the individual plant level to measure the completion percentage at that particular plant.  PM Compliance can be calculated for the different plants and tracked.

3.    PM Compliance for Peer Class assets:  PM compliance can be calculated for individual equipment groups (eg. Pumps, Motors, Transformers) or sub-groups (Centrifugal Pumps, Vertical Turbine Pumps, Horizontal Turbine Pumps, Peristaltic Pumps, Lobe Pumps etc.)

4.    PM Compliance by Criticality:  Where Equipment are classified based on their criticality, PM compliance can be calculated for all equipment that belong to a particular level of criticality

5.  PM Compliance by periodicity of schedules:  PM Compliance can be calculated for monthly PM Schedules, Quarterly PM Schedules, Annual PM Schedules etc.

6.    PM Compliance trend:  Comparison of current PM Compliance per centage to historic performance in terms of comparing with prior periods and corresponding periods in past year. (eg. Historic trend of PM Compliance for Quarterly Maintenance Schedules)

 

What are the advantages of PM Compliance?

1.    Simple:   PM Compliance is very simple and uncomplicated metric.   It is not a composite metric and thus very easy to understand. 

2.    Easy to Calculate: Calculation is very easy and can be done with simple tools – mental math, calculator or spreadsheets.

3.  Standardization:  PM Compliance calculation is a standard formula that is calculated the same way world over and across different organizations.  Standardization helps the organizations to use the same formula across different plants and units.

4.    Extensible:  While it is concise the power lies in its ability to extend to different categories – PM Compliance for different plants, periods, asset classes, criticality etc.

5.  Comparable:  PM Compliance metric can be easily compared across with peer calculations.  PM Compliance across plants can be compared.  PM compliance for a given period can be compared with the prior period for the same plant

6.  Continuous Improvement – Easily identifies the areas of improvement that the organization need to focus on to enhance Preventive Maintenance Effectiveness. 

 

How can I improve my PM Compliance?

PM Compliance can be improved in variety of ways.

1.     Improving the completion percentage of PM activities thereby increasing the numerator of the formula

2.    Certain PM activities are left out for a reason.  Analysis of these PM activities can lead to removing the redundant PMs.   Removal of such redundant PM activities decreases the numerator and provides a more authentic metric

3.    Analyzing the PM schedules to combine the PM activities that occur together (eg. Quarterly and monthly schedules)

4.    Comprehensive data analysis to find out the areas of improvement.  Data analysis can also show the focus areas (eg. Critical equipment)

5.    Improving data entry to ensure that all the activities that are completed are entered and tracked correctly.

6.    Provide tools and systems like CMMS to track the PM Compliance in a consistent and efficient way.

 

How can MaintWiz help you in managing PM Compliance?

MaintWiz is an industry 4.0 CMMS that helps you manage your Preventive Maintenance program easily and effectively.  MaintWiz can help you in tracking PM Compliance in. a variety of ways.

1.     Ready-to-use tool:

MaintWiz is a Simple and Easy-to-use CMMS software that can be set up quickly and efficiently.  It has built in tools to calculate PM Compliance that you can readily use to track the metric

2.    Visualizations and Interactive Charts:

MaintWiz provides many supporting visuals and charts, that helps understand the underlying data better.  MaintWiz Charts are interactive and can be clicked to drill down and analyze the underlying data. It also provides additional filters for you to slice and dice the data, visualize different perspectives and derive insights.

3.    Classification and Analysis:

MaintWiz provides a lot of additional analysis based on equipment hierarchy and classification.  You can easily compute PM Compliance by Plant (Facility), Unit or assembly line or for an equipment group or for a given period.

4.    Comparison:

MaintWiz supports easy comparison of PM Compliance metrics – at different plant level for a given period, for the same plant / equipment over a different periods (trend) and comparison of peer class equipment or criticality.

5.    Supplementary Metrics to improve PM Effectiveness:

It also provides many supplementary metrics like  PM Compliance On-time, overdue tasks, ageing analysis, cost of maintenance etc. that can be used together with PM Compliance to improve the overall effectiveness.


Besides these, MaintWiz can help you in defining your Preventive Maintenance Program and managing them more effectively.   MaintWiz support Time Based Maintenance, Condition Based Maintenance and Event based Maintenance.   Apart from PM Compliance it can provide more maintenance metrics for PM Effectiveness, PM Planning, Equipment Life Cycle Management and Economic Cost Computations.

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