TPM KPIs and Metrics: What to Measure in Total Productive Maintenance

KPIs

Which KPIs does TPM use?

Each MaintWiz pillar dashboard clicks through to the tags, work orders and audits behind the figure.

Three groups are visible in the table: equipment results, maintenance-system performance, and the routines that sit behind them. Report all three, because results lag behind the routines. OEE is one measure inside a TPM scorecard, not TPM itself; see OEE versus TPM (Figure 1).

TPM KPIs by pillar

Measure results and the routines that produce them: KPIs that inform each TPM pillar

• Jishu Hozen

  • Tags closed on time
  • Step audit score
  • 5S audit score

• Keikaku Hozen

  • MTBF and MTTR
  • Breakdown frequency
  • PM compliance and backlog

• Kobetsu Kaizen and Hinshitsu Hozen

  • OEE with its three factors
  • Rejection rate and repeat defects

• Kyoiku Kunren and Anzen Eisei Kankyo

  • Training hours against plan
  • Near misses closed

• Shoki Kanri

  • Vertical start-up time
  • MP sheets closed

• Office TPM

  • Office tags closed

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Read PM compliance together with failures

PM compliance (High to Low)

Failures and corrective work (Low to High)

• High compliance, low failures

  Working

  keep the plan and review intervals

• High compliance, high failures

  Tasks are wrong or poorly done

  review task content and quality

• Low compliance, low failures

  Over-maintained or lucky

  check criticality before relaxing

• Low compliance, high failures

  Plan not being done

  fix scheduling and resources

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ISO 22400-2:2014 defines OEE and the other manufacturing KPIs with their formulas, which gives every measure on a TPM scorecard one written definition.

MTBF and MTTR

MTBF and MTTR in a TPM scorecard

MTBF is operating time divided by failures and MTTR is repair time divided by failures; both rest on one written failure definition. A machine scheduled 720 hours with four failures and 10 repair hours gives MTBF 177.5 h and MTTR 2.5 h (Figure 3), and the MTBF and MTTR calculator works any failure log step by step.

Decisions to write down

Decisions to write down: what counts as a failure (stops over a set length, or any work order of a given type), whether waiting for parts is in repair time, and whether scheduled shutdowns are excluded from operating time.

MaintWiz Maintenance KPI Tracking shows breakdown count and hours by month and by day from work orders (Figure 5), and the Equipment Health Card shows each machine's breakdowns beside its PM compliance (Figure 4). Book a demo to see them on your own work orders.

Track the same measures by month in the free TPM KPI dashboard workbook.

PQCDSM

What is PQCDSM?

PQCDSM: six aims, one measure each

Where each measure lives in MaintWiz

• PProductivity

  OEE

  In MaintWiz: OEE capture

• QQuality

  Rejection rate

  In MaintWiz: Quality maintenance rejection RCA

• CCost

  Maintenance and loss cost

  In MaintWiz: Loss cost master

• DDelivery

  Schedule adherence

  In MaintWiz: Planning

• SSafety

  Near misses and incidents

  In MaintWiz: Safety, health and environment register

• MMorale

  Kaizen suggestions and training hours

  In MaintWiz: Kaizen idea sheet; education and training

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PQCDSM is a scorecard acronym used in TPM and lean programmes: productivity, quality, cost, delivery, safety and morale. It widens the view from equipment to the plant's results. Typical measures: output per hour or OEE for productivity, rejection and complaint rates for quality, maintenance cost and loss cost for cost, on-time delivery for delivery, near misses and incidents for safety, and suggestions, training and attendance for morale.

Pick one measure per letter and keep its definition fixed for the year (Figure 6).

Each machine's card in MaintWiz Asset Management shows its work orders, breakdowns and PM compliance together.

Data collection

How do you collect the data?

• OEE inputs: stops with reason codes and counts, from operators or machines; see OEE software.
• MTBF, MTTR, PM compliance and backlog: from work orders; this needs work orders to record failure start and end, cause and completion.
• Tag and audit measures: from the abnormality register and audit sheets.
• Training and safety measures: from training and incident registers.
• One owner per metric, one definition, one place for the data.

Stop reasons for OEE and MTBF are only comparable if coded consistently; the downtime reason-code library lists codes mapped to the six big losses.

How to build a TPM scorecard that gets used

• Choose five to eight measures at plant level and three to five per pillar: more will not be read.
• Show each with its definition, trend and target, and the owner's name.
• Review weekly at line level, monthly at plant level, quarterly at group level.
• Show OEE with its three factors and a loss Pareto, not OEE alone.
• Retire a measure that no one acts on.

MTBF, MTTF, MTTR

MTBF vs MTTF vs MTTR: which to use

The three abbreviations are often confused because they differ by one letter or by the type of equipment. The deciding question is whether the item is repaired and returned to service or is replaced when it fails. MTBF is the average operating time between failures of an item that is repaired and put back to work. MTTF is the average operating time until an item fails when it is replaced rather than repaired. MTTR is the average time to restore a failed item: total corrective maintenance time divided by the number of corrective actions. Treat parts lead time the same way in every job, in repair time for all or for none.

A worked structure

For a repairable machine, MTBF and MTTR come from operating time, the failure count and total repair time, as in Figure 3. For a bearing replaced at each failure, with life spans of 4,000, 5,200 and 4,800 hours in service, MTTF is the average of the three, 4,666.7 hours. The bearing's replacement time is not part of MTTF; it belongs to the maintenance of the machine that holds it.

Report MTBF and MTTR for each equipment, not as a plant average: a plant figure hides the one machine that fails every week. Rank equipment by failures and by repair hours, and start improvement projects at the top of both lists.

What to write down

• Whether each item is repairable or replaced, so the right measure is used.
• What counts as a failure: any work order of a given type, or stops longer than a set length.
• Where repair time starts and ends, and whether waiting for parts is in it.
• Whether scheduled shutdowns are excluded from operating time.

The MTBF and MTTR calculator applies the repairable-item formulas, and the downtime reason codes page shows how to classify stops so the failure count is consistent.

Sources

Sources

• BSI PAS 1918:2022, Total Productive Maintenance: implementing key performance indicators, guide (catalogue entry). https://knowledge.bsigroup.com/products/total-productive-maintenance-tpm-implementing-key-performance-indicators-guide
• ISO 22400-2:2014, Automation systems and integration: Key performance indicators (KPIs) for manufacturing operations management, Part 2: Definitions and descriptions https://www.iso.org/standard/54497.html