Some maintenance jobs can be costing more than you thought!
Maintenance managers usually look at maintenance data by equipment to identify equipment that is getting expensive to maintain. However, there are other ways to to slice your data and look for ways to reduce costs and improve effectiveness. For example consider the costs of different maintenance tasks or jobs. This is especially relevant when you may have lots of very similar equipment. You may have several pumps of the same model, several similar HVAC units and so on.
In such cases all these equipment have very similar maintenance cycles. You may have done a good job and identified and fixed all the bad apples in the bunch. However, an underlying issue may be that this model of equipment really requires far too much maintenance – preventive or corrective. It may be time to do a wholesale replacement of this type of equipment with a new model or something else. Doing such a full replacement can be very expensive. It is often disruptive. So you really need to have an idea of what the old equipment is costing you before you jump on doing such a replacement.
Equipment maintenance analytics with maintenance task data
One of the reports you can use is a task history report. This allows you to compare costs and work order duration by different maintenance tasks. Say you have maintenance tasks specific to a class of equipment. For example it could be HVAC units you use in your facility. With the task history report you have a way of identifying how much these units are costing in time and money. You want to make sure that most of these costs are not due to a few bad apples. This means just a few equipment that keeps failing is responsible for most of the work. This is where the equipment history report for the same period can be useful. You can see if the higher costs are due to just some equipment. Or it may be that equipment model is expensive to maintain.
The task history report allows you to compare different types of task costs. You can compare labor costs, material (parts & supplies) costs and so on. You may find that some task maintenance costs are rather high because of very expensive spare parts. Alternative part suppliers could help reduce such costs. If labor costs are very high you can dig in to find the reason. Maybe you need expensive outside subcontractors with specialist skills to complete the work. You could reduce costs by getting training and building in-house skills.
For example look at the screenshot below of a task history report from our FastMaint CMMS software. We may wish to dig into why Air Compressor – Weekly Service has a much higher duration and cost than other tasks. The reason could be rather benign. You may have many air compressors. So lots of work orders are created for the weekly service on each of them. Or you may decide that they are getting expensive to maintain. It may be time to change to a newer model of air compressor.
We see that using a combination of an equipment history report with a task history report allows us to aggregate data in two different ways. This can uncover issues and trends not just with some equipment. Possibly a whole class of equipment needs replacement or changes in the maintenance program.
Other useful maintenance metrics
Using data from your maintenance management software you can get several other useful metrics that can be helpful to improve your maintenance program. You can get our free guide “Key Maintenance Management Metrics for Maintenance Planners” for more information.Download Key Maintenance Metrics