Cost of unplanned downtime
What breakdowns cost you in lost production over a year. Use your own currency.
Your downtime cost is
Cost
Saving from planned repairs
A repair costs less when you can plan it than when it is an emergency. This shows what that difference is worth over a year.
Your saving is
Payback period
How long it takes for the saving to cover what monitoring costs you each year.
Your payback period is
Maintenance cost per machine
What you spend on maintenance for each machine, on average, over a year.
Your cost per machine is
Maintenance cost against replacement value
Your yearly maintenance spend as a share of what it would cost to replace the equipment. It shows whether you are spending a little or a lot to keep it running.
Your maintenance cost is
Reliability
Mean time between failures (MTBF)
How long a machine runs, on average, before it breaks down again. A higher number is better.
Your MTBF is
Mean time to repair (MTTR)
How long, on average, it takes to get a broken machine running again. A lower number is better.
Your MTTR is
Availability
The share of the time a machine was needed that it was actually able to run.
Your availability is
Failure rate
How often a machine breaks down for the time it runs. A lower number is better.
Your failure rate is
Overall equipment effectiveness (OEE)
One figure for how well a machine is used. It combines how often it was available, how fast it ran, and how much of what it made was good.
Your OEE is
Maintenance work
Planned maintenance percentage
How much of your maintenance work is planned ahead, and how much is reacting to breakdowns.
Your planned maintenance is
Preventive maintenance compliance
How many of the preventive jobs you scheduled were actually done on time.
Your compliance is
Schedule compliance
How closely the team kept to the week's plan. It counts all scheduled work, not only preventive jobs.
Your schedule compliance is
Wrench time
The share of a technician's paid hours spent with tools in hand, as opposed to travelling, waiting for parts, or doing paperwork.
Your wrench time is
Getting started
Sensors for a line
A first count for a pilot. One sensor goes on each bearing housing you want to watch. The final number is agreed with us at scoping.
You need
How to use these
This is arithmetic, not a promise. Each calculator works on the numbers you give it and claims nothing about what will be found on your equipment.
Use your own numbers
Take them from your maintenance records for the last year. An industry average tells you about someone else's plant.
One machine, one period
Keep each sum to a single machine or line, and use the same stretch of time for every number you enter.
Bring the answers with you
These figures are a good starting point for a technical review. We will go through them with you against your own asset list.