Maintenance Management Benchmarking and Performance Analysis

Chapter 6: Comparisons and Conclusions

To compare maintenance indicators, we evaluated factors involving maintenance practices, preventive maintenance levels, and equipment status. We surveyed six companies using a questionnaire directed at maintenance managers, supervisors, and mechanical staff responsible for maintenance activities.

The questionnaire consists of 285 total points, with each question rated on a scale of 1 to 5. By averaging the scores from managers and maintenance workers, we determined the extent to which each company achieves successful maintenance management.

Interpreting Questionnaire Results

A score of 100% (285 points) indicates the following:

• Staff Integration: Personnel are fully integrated into maintenance activities with deep knowledge of procedures, techniques, and tools.
• Continuous Training: Employees receive ongoing training and possess the ability to identify and repair faults efficiently.
• Communication: Inter-departmental communication is excellent.
• Administrative Efficiency: The company utilizes and adheres to an efficient maintenance administration technique.
• Employee Development: The organization actively promotes competitiveness and professional growth.
• Equipment Health: Machinery is well-maintained, operating within its lifecycle, and meeting product quality standards.

The Role of Human Resources in Maintenance

While technology and automation reduce human error, maintenance remains a human-centric discipline. A lack of training, skills, motivation, or procedural knowledge can exacerbate equipment issues rather than providing quick solutions.

Global Maintenance Benchmarking

According to the Pan American Committee for Maintenance Engineering, developed nations (such as Canada, the USA, and France) allocate between 7% and 18% of their annual income to maintenance, whereas developing countries often exceed 35%.

Survey Findings: TPM vs. Traditional Maintenance

Our survey results highlight the impact of Total Productive Maintenance (TPM):

• Standard Companies: Average idle time is 30%, with 60% of time dedicated to corrective work. These companies employ an average of 45 people across three shifts.
• TPM-Implemented Companies: Average idle time is reduced to 15%, with only 10% dedicated to corrective work. These companies operate efficiently with an average of 14 staff members across three shifts.

Proper maintenance administration significantly reduces labor costs and improves operational output.