Top 27 Maintenance KPIs and Metrics You Should Be Measuring This Year

Maintenance KPIs List

Maintenance KPIs are metrics that track and measure the maintenance manager, employee, and team’s ability to ensure that the organization’s machinery and equipment maintenance plan is successfully implemented. The maintenance department is primarily responsible for all of the organization’s maintenance requirements.

Maintenance Team Objectives

The maintenance team objectives or KPIs are designed to track and measure the maintenance team’s operational efficiencies, including metrics like reducing unscheduled downtime, reducing maintenance costs, improving the mean time between failure analysis, improving the work order cycle time, and improving the assets’ (machinery and equipment) lifecycles.

  • Improve (reduce) unscheduled downtime – Unscheduled downtime is one of the top concerns of manufacturing plants and can be harmful to the organization’s productivity and profitability metrics. This KPI tracks and measures the maintenance team’s ability to improve or reduce the unscheduled downtime metrics.
  • Improve (reduce) maintenance costs – Maintenance expenses are costs incurred on a regular basis to keep an asset (machinery or equipment) working in its optimal condition. This KPI measures the maintenance team’s ability to improve or reduce maintenance costs. The higher this KPI, the greater the extent to which the team can reduce maintenance costs.

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  • Improve the Mean time between failure (MTBF) – The Mean time between failures (MTBF) is the predicted elapsed time between inherent failures of a mechanical or electronic system during normal system operations. This KPI tracks and measures the maintenance team’s ability to improve the MTBF metric over time.
  • Improve work order cycle time – The work order cycle time is the time it takes for the work order lifecycle to complete, from the time the order is created to the time the work is completed. This KPI tracks the maintenance team’s ability to improve the work order cycle time.
  • Improve the Root Cause Failure Analysis (RCFA) – The Root Cause Failure Analysis (RCFA) is a systematic way of reviewing all the evidence from a failure to determine a root cause that is manageable and prevent a recurrence, reducing the risk of repeated failures. This KPI tracks and measures the maintenance team’s ability to improve the RCFA metrics.
  • Improve work orders – Work orders are designed for preventative and corrective maintenance, reducing the risk of unplanned downtime. This KPI tracks and measures the maintenance team’s ability to improve the work order metric. The higher this KPI, the greater the extent to which the team can improve the work order numbers.
  • Improve asset lifecycle – An asset lifecycle is the series of stages involved in the management of an asset. This KPI tracks and measures the extent to which the maintenance team is able to maintain the asset as part of its lifecycle, ensuring that the asset functions optimally throughout its lifespan.

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Maintenance Employee Objectives

The maintenance employee objectives or KPIs are designed to track and measure the maintenance employee’s operational efficiencies over time. Metrics measured include improving the reactive maintenance work hours, improving the work orders completed on time, improving the maintenance response time, and keeping up with the scheduled maintenance requirements.

  • Improve (reduce) reactive maintenance work hours – Reactive maintenance or breakdown maintenance refers to repairs done when equipment has already broken down to restore the equipment to its normal operating condition. This KPI tracks and measures the maintenance employee’s ability to improve or reduce the reactive maintenance work hours.
  • Improve work orders completed on time – Work orders must be fulfilled within their stated due date. The work orders completed on time KPI is designed to track and measure the maintenance employee’s ability to complete the work order on time. The higher this metric, the greater the employee’s ability to complete work orders on time.

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  • Improve maintenance response time – The maintenance response time is the time it takes for the maintenance employee to respond to the request to maintain equipment or machinery. The higher this KPI, the greater the employee’s ability to respond to maintenance requests on time.
  • Maintain all machinery to ensure they are always at working standards – This KPI tracks and measures the maintenance employee’s ability to maintain all machinery to ensure they are always at working standards. The higher this metric, the greater the maintenance employee’s ability to consistently maintain all machinery, making sure that there is minimal downtime.

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Maintenance Manager Objectives

The maintenance manager’s objectives or KPIs are designed to track and measure the maintenance manager’s to fulfill the operational efficiencies attached to the role. Metrics measured include planning and managing the repair and installation activities, prepare daily reports and maintenance logs, overseeing the maintenance budget.

  • Improve (reduce) the work order costs – The work order costs are the total costs of the work orders over time. This KPI tracks and measures the maintenance manager’s ability to reduce the work order costs over time. The higher this metric, the greater the extent to which the manager is able to reduce these costs.
  • Maintenance inventory and budget – The maintenance inventory and budget are designed to ensure that the maintenance team does not overspend and that the inventory includes items necessary to maintain machinery and equipment. This KPI tracks and measures the maintenance manager’s ability to manage the maintenance inventory and budget.

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  • Improve preventive versus reactive – Maintenance falls into two categories: preventative or reactive. Preventative maintenance focuses on avoiding repairs and asset failure through preventive and predictive methods. Reactive maintenance focuses on repairing an asset once failure occurs. This KPI measures the maintenance manager’s ability to implement a preventative maintenance strategy.
  • Plan and manage all repair and installation activities – This KPI tracks and measures the maintenance manager’s ability to plan and manage all repair and installation activities. The higher this metric, the greater the extent to which the maintenance manager can design and implement a robust machinery and equipment repair and installation strategy.
  • Assign repair schedules and evaluate repair cost estimates – This KPI tracks and measures the maintenance manager’s ability to assign repair schedules and evaluate repair cost estimates. The higher this metric, the greater the extent to which the maintenance manager is able to allocate repair schedules and evaluate repair cost estimates
  • Document and prepare daily progress reports and maintenance logs – The daily documentation and preparation of progress reports and maintenance logs are an integral part of the maintenance manager’s role. This KPI tracks and measures the maintenance manager’s ability to prepare daily progress reports and maintenance logs. The higher this metric, the greater the maintenance manager’s job efficiencies.
  • Track expenses and oversee the maintenance budget – The ability to track expenses and oversee the maintenance budget is imperative to the maintenance manager’s role. This KPI measures the maintenance manager’s ability to track costs and oversee the maintenance budget. The higher this metric, the greater the manager’s ability to monitor expenses and manage the maintenance budget.
  • Coordinate the completion of complex repairs – The coordination of the completion of complex repairs is integral to the maintenance manager’s role. This KPI tracks and measures the extent to which the maintenance manager is able to coordinate the completion of complicated repairs. The higher this metric, the greater the manager’s operational efficiencies.
  • Ensure that the facility satisfies all industry regulations – The successful maintenance manager must ensure that the organization’s facility satisfies all industry regulations. This KPI tracks and measures the extent to which the maintenance manager makes sure that the company’s premises meets all industry regulations.

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These maintenance KPIs are an integral part of ensuring that the maintenance employee, team, and manager meet their key organizational efficiencies. The successful implementation of the maintenance strategy plays an indispensable role in ensuring that its machinery and equipment are kept in optimal condition over time. As a result, measuring these objectives is key to organizational success. They focus on tracking metrics grouped in three result areas: maintenance employee, team, and manager.

It is necessary to track and measure these KPIs over time because they offer insight into the maintenance department’s efficiencies and where improvements are needed. Metrics like reducing unscheduled downtime, managing the budget, tracking expenses, reducing the maintenance response time, and preparing progress reports are integral to ensuring operational success for the whole organization.

Implementing maintenance objectives for the maintenance team, employee, and manager drives the need to ensure consistency over time. High-performing metrics are valued, translating into an effective maintenance strategy and application by the maintenance team. Juxtapositionally, low-performing metrics must be revisited as they indicate poor performance and detract from operational and organizational success metrics.

Benefits of AssessTEAM cloud-based employee evaluation form for your maintenance team.

  • Use on all devices
  • Include custom KPIs
  • Keep historic trends
  • Include eSignatures
  • 360-degree feedback
  • Unlimited customization

A guided rollout is included with all our plans. Simply send us your job descriptions and we will set up your evaluations.
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