Optimal maintenance KPIs: Efficiency along the asset lifecycle

Author: Kerstin Schröer, Senior Consultant at Orianda Solutions AG – a valantic company

In today’s business world, which is characterized by constant change and growing competitive pressure, asset maintenance is increasingly becoming a key component of a company’s success.

In this article, we will take an in-depth look at maintenance KPIs, with a special focus on the lifecycle of an asset. The interaction between purchasing, production and maintenance as well as the use of design data and technical diagnostic procedures are of crucial importance.

Maintenance in the lifecycle of an asset

The life cycle of an asset extends from planning and construction through to use and finally decommissioning. In each of these phases, there are certain challenges and opportunities that affect maintenance. An effective maintenance policy and maintenance strategy should therefore take the entire life cycle into account.

Interaction between purchasing, production and maintenance

Close cooperation between the purchasing, production and maintenance departments is crucial in order to optimize maintenance KPIs. Let’s start with purchasing: here it is important to ensure that the assets are of high quality and meet the respective requirements. This can be achieved by taking design data and technical specifications into account. Involving maintenance in the procurement process at an early stage can help to identify and avoid weak points as early as the design phase.

Production also contributes to optimization by operating assets according to manufacturer specifications and maintenance recommendations. Smooth operation minimizes wear and tear and increases the service life of the assets.

Use of design data and technical diagnostic procedures

Design data and engineering diagnostics must be used to identify weak points at the source and prevent future failures. The maintenance teams should have access to the original plans, specifications and design data in order to carry out targeted root cause analysis. This makes it possible to better understand failures and malfunctions.

By analyzing failure diagnoses and frequencies, maintenance teams can identify patterns and take preventative measures. This not only leads to a reduction in downtime, but also to a reduction in maintenance costs.

Maintenance KPIs for success

Maintenance metrics are crucial to measuring the success of the maintenance strategy. Here are some key performance indicators and areas of analysis that can be considered:

1. Overall Equipment Effectiveness (OEE): OEE measures the efficiency of your assets and takes into account downtime, loss of speed and quality issues. A high OEE indicates efficient system performance.
2. Mean Time Between Failures (MTBF): This is the average time between two failures of an asset. A higher MTBF indicates a more reliable asset.
3. Fault and cause catalogs: These catalogs collect information on frequently occurring faults and their causes. They are valuable tools for root cause analysis and prevention.
4. Condition monitoring: Continuous monitoring of the condition of assets enables early detection of wear or problems. This can support planned maintenance work.

Maintenance in comparison: retrofit vs. new acquisition

An important aspect of maintenance in relation to the life cycle is the decision as to whether it is worthwhile to incur higher maintenance costs and greater risk for an older machine compared to a new acquisition with new technological advantages. This decision should be based on sound maintenance metrics.

If an older machine can be modernized through retrofit, reducing maintenance costs and downtime, this can be an economically viable option. In some cases, this can even extend the life of the asset and reduce the total cost of ownership.

Conclusion: Asset lifecycle management as the key to success

Maintenance metrics are undoubtedly crucial to optimizing the lifecycle of an asset. They enable companies to monitor the performance of their assets, identify weak points and make strategic decisions. However, maintenance metrics alone are not enough to ensure sustainable success. The key lies in the holistic approach of asset lifecycle management.

Asset lifecycle management refers to the comprehensive management of assets throughout their entire lifecycle, from planning and procurement to commissioning, use and ultimately disposal. The integration of maintenance KPIs into this management concept is of crucial importance.

The continuous availability of information along the entire asset lifecycle enables companies to make better decisions. This not only extends the life of assets, but also reduces the total cost of ownership. It helps to increase efficiency, minimize risks and increase competitiveness.

A central element of asset lifecycle management is the close cooperation between the purchasing, production and maintenance departments. This cooperation ensures that the right decisions are made right from the start, whether in the procurement of high-quality assets or in the implementation of preventive maintenance measures.

Key maintenance figures serve as a guide for continuous improvement. They enable companies to closely monitor the condition of their assets, minimize downtime and increase overall efficiency.

In conclusion, maintenance KPIs combined with holistic asset lifecycle management are the key to a company’s long-term success. By effectively managing the entire lifecycle of their assets and using maintenance metrics as part of this strategy, companies cannot only increase their profitability, but also ensure sustainable and competitive operations.