Industrial processes:.
Production KPIs are essential when tracking a company's production and results. Where, depending on the case, different production indicators can be found. However, there are a series of KPIs that, due to their importance, will be common to all companies, so it is essential to have them in data analysis.
What are the main production KPIs?
The choice of production KPIs to reference can vary from company to company. However, we are going to find some common ones among all of them due to the special importance they have when carrying out data analysis and evaluating the results obtained.
• Production cycle time:
It allows you to measure the time it takes to produce a given product taking into account the production batch. To do this, the moment in which the production order is executed is taken as an initial reference and as a final reference the moment in which the batch in question can be considered completed. In other words, the production time of the batch is taken and divided into conforming units. Why is it not also based on the non-compliant units, because the nature of the process already includes the percentage of non-compliant units (obviously ignoring that the process must be adjusted). The time that elapses between one moment and another is the production cycle time of each product.
• Quality performance:
In this case, the production KPI focuses on analyzing the percentage of products that are manufactured without errors. That is, the number of products that, at the end of the production chain, are perfect from the point of view of the company's quality standards.
• Rejection rate:
The rejection rate is a KPI that measures products that do not meet certain quality standards. That is, it is the opposite KPI to quality performance, since, in this case, what is measured is the quantity of products that are eliminated from the supply chain before completing their production.
• Return rate:
This production KPI refers to the tracking of the product once production has been completed. However, it is essential to take it into account to adapt production and reduce the rate of returns, since it directly determines the level of customer satisfaction. A high return rate when the product meets certain quality standards is usually associated with ineffective design or an inability of the product to meet consumer expectations, so in many cases it will be necessary to reformulate production from the beginning.
Maintenance process:
Maintenance key performance indicators (KPIs) are metrics that evaluate factors critical to the success of an organization. A wide range of companies track KPIs. However, in the world of maintenance, these metrics monitor performance against targets tied to things like machine failures, repair times, maintenance delays, and costs.
What are the main maintenance indicators?
Although KPIs have a direct relationship with the objectives to be achieved, they are not goals. A maintenance KPI is a metric that is used to quantitatively evaluate the performance of a certain activity, asset or department.
The indicators can be divided into two categories:
• Those that highlight the effect of maintenance on business performance
• Those associated with the reliability and availability of assets.
From this categorization, we can highlight the main KPIs: downtime; backlog; MTBF; MTTR; OEE; PMP (planned maintenance percentage/planned maintenance rate) and preventive maintenance compliance rate. Below, we will explain their respective functions, benefits and what the global average patterns are for each of the indicators.
• Downtime
This maintenance metric, also known as Equipment Downtime, can be used to track, monitor and evaluate the reliability of an asset.
Downtime corresponds to the time of unscheduled inactivity. That is, it is the result of an unforeseen event that will require some type of intervention. This KPI can be evaluated, regardless of whether a maintenance schedule already exists (or not) for the equipment.
• Backlog
The backlog is a time indicator that can be translated as “maintenance delay.” It represents the accumulation of activities pending or in execution, for each technician or employee, regardless of whether they are already underway or are still only planned. In other words, the Backlog is the service time necessary to perform a specific Corrective, Preventive or Predictive Maintenance action; Quality Inspections; Improvements or any other activity for the proper functioning of the assets.
• MTBF – Mean Time Between Failures
Another important maintenance performance indicator is the MTBF, also known as the Reliability Indicator. It measures the rate of random (unforeseen) failures, even if they are caused by software failures or manufacturing defects that compromise its useful life. Failures that do not cause downtime are excluded.
• MTTR – Mean Time To Repair
An equally common maintenance indicator is the Mean Time to Repair (MTTR), which can be applied to an equipment, machine, component or system. The MTTR considers the average time it takes your technical team to intervene or resolve a breakdown after it has occurred. Unlike MTBF, the objective is to reduce this maintenance KPI as much as possible. In a way, the reduction of the MTTR serves as a trigger to make decisions that improve your maintenance strategy, always with the objective of maximizing benefits and reducing risks. It is widely used in processes where the loss of benefits due to inactive machinery is significant.
• OEE – Overall Equipment Effectiveness
This is one of the most important maintenance KPIs as it measures the overall effectiveness of the company. With this calculation it will be possible to establish whether the processes are efficient or not. One of the benefits of calculating OEE is knowing how often equipment is running. It also helps us know how quickly the company's production is developing and, finally, how many products (or services) have been produced (or made) without any type of failure.
• PMP – Planned Maintenance Percentage
The Planned Maintenance Percentage considers the time dedicated to scheduled activities (whether maintenance, repair or replacement) with the defined assets. This maintenance KPI is directly associated with a company's Preventive Maintenance Plan. Efficiency is considered, the way in which each activity has passed, as well as the time necessary to complete it, the result of the PMP will indicate the degree of efficiency of a company, as well as its performance and success in the market sector in which it operates.
• Preventive Maintenance Compliance Rate
This metric could not be missing from a list of the main maintenance performance indicators. Analyzes the company's compliance with the established schedule.
Electrical sector process:.
• SAIFI: This indicator refers to the average number of times an interruption occurs for a user.
• SAIDI: Refers to the average duration of interruptions perceived by a user.
• CAIFI: Represents the average number of interruptions that an interrupted customer experiences during a given period of time. It is particularly used to compare situations over several years, where at the time of its application, accepted clients must be counted only once, regardless of whether they have suffered more than one interruption throughout the year.
• CAIDI: This indicator refers to the proportion between the SAIDI indices (average duration of service interruptions) and the SAIFI (average quantity or frequency of interruptions), that is, it is the ratio between both indicators (SAIDI/SAIFI).
• ASAI: This indicator refers to the average availability of the service and is the numerical relationship between the total number of hours that the service was available and the total number of customer hours demanded in a certain time interval.
• ENS: It is one of the most important parameters that we need when evaluating load indices.
• ACCI: In English “Average customer curtailment index”, it is a consumer restriction index.