What is Planned Maintenance Percentage (PMP) & How To Calculate It?
Planned Maintenance Percentage (PMP) is a key performance indicator used in maintenance management to measure the proportion of maintenance tasks that are planned ahead of time. It is a pointer to the effectiveness of your preventive maintenance plan, as it gauges the amount of maintenance performed based on a strict schedule, compared to the full quantity of work accomplished.
In essence, the PMP provides an estimation of the regimen and predictability of maintenance tasks in an organization.
To calculate the Planned Maintenance Percentage, use the formula:
PMP = (Planned Maintenance Tasks / Total Maintenance Tasks) x 100
Why is Planned Maintenance Percentage Important?
PMP establishes its significance from its ability to reflect on the effectiveness of maintenance planning and scheduling. High PMP means that the maintenance tasks are mostly planned, and the management has control over when, how, and by whom the tasks should be done. This decreases the possibility of unexpected equipment failure, enhances operational efficiency, and saves costs.
Key Features of Planned Maintenance Percentage
- Preventive Orientation: PMP indicators are primarily designed to push operations towards preventive maintenance, instead of being reactive. The goal is to find optimal maintenance schedules to prevent equipment failure and reduce downtime.
- Control Measure: A higher PMP often indicates more control over the workshop by management. It spells a lower risk of unexpected equipment failures and ergonomic hazards.
- Cost-saving: By studying PMP and using it as a tool to optimize maintenance tasks, organizations can estimate and control maintenance costs more efficiently.
Benefits of Planned Maintenance Percentage
The effective use of PMP can bring a plethora of benefits to an organization in terms of cost efficiency, productivity, safety, and more.
- Predictability: It makes maintenance tasks more predictable, as it emphasizes planning ahead and scheduling tasks in advance.
- Reduced Risks: It helps to trim down the risks of equipment failure and subsequent downtimes.
- Efficiency Boost: By ensuring routine check-ups and preemptive repairs, the overall efficiency of the equipment can be heightened, contributing to the productivity of the workforce.
- Asset Longevity: Regular maintenance also enhances equipment longevity and reduces overall investment in machinery over time.
How to Implement PMP Effectively?
Successful implementation of PMP hinges on a well-thought-out plan of action:
- Effective Planning:
- Creating a regular schedule for maintenance tasks is crucial. Tasks should be prioritized based on need.
- Use of Technology:
- Using maintenance management software to track equipment status and maintenance tasks can save time and improve accuracy.
- Training the Team:
- Ensure the maintenance team is well-versed in preemptive practices, as human error is often a significant cause of failure.
- Periodic Review:
- Regularly review the PMP and its effectiveness in achieving desired results and make necessary adjustments.
Top 5 FAQs about Planned Maintenance Percentage
- Does a 100% PMP mean optimal maintenance? Not necessarily. An excessively high PMP could indicate over-maintenance, which might be leading to wastage of resources.
- What is an ideal PMP level? While there is no one-size-fits-all answer, a PMP of around 90% is commonly accepted as an effective level of maintenance planning.
- How often should PMP be calculated and monitored? The frequency greatly depends on the operational routine and the industry. However, monthly or quarterly reviews are generally recommended.
- How can low PMP be improved? More emphasis on planning and preventive maintenance practices, with adequate training for the team, can steadily enhance the PMP.
- How can technology aid in PMP? Maintenance software can automate scheduling and tracking of maintenance tasks, making the calculation and evaluation of PMP easier and more accurate.
