Maintenance KPI Dashboard | ENG. Mahmoud Hassan

⚙️ Plant Setup

✏️ Manual Input

📥 Maximo Upload

📊 KPI Dashboard

📈 Trends

💡 Insights

📚 Formulas

⚙️ Plant Information & Targets

ℹ️

Define your plant details and KPI targets. Industry benchmarks (SMRP) are pre-filled but can be customized for your operation.

📋 Plant Details

Plant Name *

Plant Type

Location

Reporting Period *

🎯 KPI Targets (Customize per your plant)

⚠️

Default targets are based on SMRP world-class benchmarks. Adjust based on your operation maturity level.

Availability Target (%) *

SMRP World-Class: ≥ 95%

OEE Target (%)

World-Class: ≥ 85%

PM Compliance Target (%) *

SMRP: ≥ 90%

Schedule Compliance (%)

SMRP: ≥ 85%

Backlog Target (weeks)

Healthy: 2-4 weeks

PM/CM Ratio Target (%)

PM should be ≥ 70% of work

MTBF Target (hours)

Industry-specific

MTTR Target (hours)

Lower is better

✏️ Manual Data Entry

ℹ️

Enter the operational and maintenance data for the period. The system will calculate all KPIs automatically using SMRP formulas.

📅 Reporting Period

Period Start Date *

Period End Date *

Number of Assets in Plant

⏱️ Operating Time & Downtime (in hours)

Total Calendar Hours *

For monthly: 720h | weekly: 168h

Total Operating (Uptime) Hours *

Unplanned Downtime (h) *

Failures, breakdowns

Planned Downtime (h)

Scheduled PM, shutdowns

🔧 Failures & Repairs

Number of Failures *

Equipment breakdowns in period

Total Repair Time (h) *

Sum of all repair durations

Number of Repairs Completed

📋 Work Orders (Maintenance)

PM Work Orders Scheduled *

PM Work Orders Completed *

Completed on-time

CM (Corrective) Work Orders

Reactive work

Total Work Orders Planned

Planned WOs Completed

Open WOs at Period End

Used for backlog calculation

👷 Labor & Workload

Total Maintenance Hours Worked

PM Labor Hours

CM Labor Hours

Estimated Hours per Open WO

For backlog (default: 4h)

⚙️ Production / Performance (Optional - for OEE)

Performance Rate (%)

Actual / Design output

Quality Rate (%)

Good / Total production

📥 Upload Maximo Work Order History

💡

📁

Drop your Maximo WO export here or click to browse

Supports: Excel (.xlsx/.xls), CSV

📊

No Data Yet

Setup your plant and enter data to see KPIs

📈

KPI Trends

Need at least 2 reporting periods to see trends

💡

Insights & Recommendations

Calculate KPIs first to get intelligent recommendations

📚 KPI Formulas (SMRP & ISO 14224)

📐 MTBF — Mean Time Between Failures

MTBF = Total Operating Hours / Number of Failures
Higher is better — measures reliability between breakdowns

📐 MTTR — Mean Time To Repair

MTTR = Total Repair Hours / Number of Repairs
Lower is better — measures maintainability/response time

📐 MTTF — Mean Time To Failure

MTTF = Total Operating Time / Number of Failures
For non-repairable items (replaced after failure)

📐 Availability

Availability = MTBF / (MTBF + MTTR) × 100%
Or: Uptime / (Uptime + Downtime) × 100%
World-class: ≥ 95%

📐 Reliability R(t)

R(t) = e^(-t/MTBF)
Probability of operating without failure for time t

📐 OEE — Overall Equipment Effectiveness

OEE = Availability × Performance × Quality
World-class: ≥ 85% | Typical: 60-70%

📐 PM Compliance

PM% = (PM WOs Completed On-Time / PM WOs Scheduled) × 100%
SMRP target: ≥ 90%

📐 Schedule Compliance

SC = (Planned WOs Completed / Total Planned WOs) × 100%
SMRP target: ≥ 85%

📐 Backlog (in weeks)

Backlog = (Open WOs × Hours per WO) / (Crew size × 40h)
Healthy: 2-4 weeks | < 2 = under-loaded | > 6 = overloaded

📐 PM/CM Ratio

PM/CM = PM Hours / Total Maintenance Hours × 100%
Best practice: PM should be ≥ 70%

🏆 SMRP World-Class Benchmarks

KPI	World-Class	Average	Poor
Availability	≥ 95%	85-94%	< 85%
OEE	≥ 85%	60-84%	< 60%
PM Compliance	≥ 90%	70-89%	< 70%
Schedule Compliance	≥ 85%	65-84%	< 65%
Backlog (weeks)	2-4	4-6	> 6 or < 2
PM/CM Ratio	≥ 70%	50-69%	< 50%
Reactive Work %	≤ 20%	20-40%	> 40%

📖 References

SMRP Best Practices, 5th Edition (2017) — Society for Maintenance & Reliability Professionals
ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data
ISO 55000:2014 — Asset management — Overview, principles and terminology
EN 15341:2019 — Maintenance Key Performance Indicators
Wireman, T. (2005) — Developing Performance Indicators for Managing Maintenance
Mobley, R. K. (2002) — An Introduction to Predictive Maintenance