It’s no secret that over the past decade improved technology has made it easier and less time consuming to gather the data necessary to track essential Key Performance Indicators (KPIs). As a Mechanical Integrity (MI) manager in today’s technology-driven world, you now have information readily available at the tip of your fingers.

Mobile technology makes it possible to see data as it is being entered in the field, eliminating the need to wait days or even weeks before you’re able to get the information you need to make well-informed decisions. Up-to-date or even real-time information is now readily displayed on a KPI dashboard, and you can use that information accordingly to be more proactive as a manager.

KPI Dashboards

Not surprisingly, KPI dashboards have become increasingly popular in recent years. They allow you to pick and choose which KPIs you need to monitor on a daily basis to meet your facility’s strategic goals in the safest and most cost-efficient way.

KPIs provide critical snapshots of how your plant is operating, and more importantly, how your plant should be operating to maintain your competitive advantage. However, it can be challenging to determine which KPIs add the most value to your dashboard.

Choosing the Right Dashboard KPIs

As the person responsible for mechanical integrity inside your facility, three important KPIs you may want to consider adding to your dashboard are:

  1. Breakdown Maintenance KPIs
  2. PM Compliance KPIs
  3. Fixed Equipment Inspection KPIs

Breakdown Maintenance KPIs

KPIs that track breakdown maintenance give you an idea of how much you’re spending to repair or replace equipment. They allow you to see how often equipment is breaking and if it’s failing earlier than anticipated. These KPIs make it easier to diagnose recurring breakdowns and calculate average downtime across your facility. They also help you determine why you are doing repairs and what can be done to remove the causes of those repairs. By tracking breakdown maintenance, your maintenance team can develop internal benchmarks to pinpoint inefficiencies and make more informed decisions that improve plant uptime and reliability.

PM Compliance KPIs

Even though most codes allow you to go up to 15 months before completing a PM and still remain compliant, completing even non-critical PMs on time makes it possible to spot defects before they evolve into something more severe, like asset failure.

When equipment fails, it can be costly, even if you’re dealing with non-critical components. Maintenance hours go up and maintenance teams are pulled away from regular PMs to handle breakdown maintenance tasks, which in turn can drop your PM compliance percentage and put your plant at risk for even more asset failure, creating a vicious cycle. All things considered, the bottom line is this: when PMs start to slip, equipment starts to break and costs start to escalate.

KPIs that track PM compliance give you an idea at 30, 60, or 90 days how many items have not been completed on their PMs, and how many days they are overdue. They also help you gauge how difficult it is for you to maintain your current PM schedule in addition to giving you an idea of how much you’re reactive versus proactive. Equally important, they give you an opportunity to monitor and improve your PM program. These KPIs will help you determine if your PM program is working, or if it needs to be adjusted with either more or less frequent PMs to achieve the desired level of reliability.

Fixed Equipment Inspection KPIs

Timely fixed-interval inspections are extremely important for fixed equipment since fixed equipment doesn’t have sensors to monitor for corrosion and damage in real time, and the damage is oftentimes not immediately apparent. Fixed equipment inspection KPIs help you manage inspection intervals, as well as overdue inspections, and help you track important details picked up during an inspection.

Fixed equipment inspection KPIs essentially show you whether or not you’re seeing exactly what you expected to see. For example, if you changed the inspection interval of a piece of equipment and allowed it to go out to five years, are you getting the results you anticipated? Do you need to shorten the interval? Is the risk higher than anticipated? Evaluating the data obtained from these KPIs can help you monitor and improve your fixed equipment inspection plans.

Conclusion

At the end of the day, as an MI manager you know how important it is to measure plant performance. Whether the goal is to mitigate risk, minimize cost, or increase compliance, Key Performance Indicators (KPIs) provide the data you need to make better, more informed decisions, and leveraging effective KPI Dashboards has made it easier than ever to access that data quickly and efficiently.

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