Planned maintenance percentage

What is planned maintenance percentage?

Planned maintenance percentage (PMP) is a maintenance metric that measures the number of planned maintenance tasks in comparison to all maintenance tasks. PMP is expressed as the percentage of total maintenance hours spent on planned maintenance tasks in a given period.

Planned maintenance percentage is a valuable metric for tracking the health of a preventive maintenance program and identifying opportunities to reduce reactive maintenance. PMP can also be used to pinpoint the cause of failure, inefficiencies, and broken maintenance processes so they can be fixed.

How is PMP calculated?

Planned maintenance percentage is calculated by dividing the total number of planned maintenance hours in a given period by the total number of hours spent on all maintenance in the same period. This number is multiplied by 100 to give you the final percentage.

PMP = # of planned maintenance hours ÷ # of total maintenance hours × 100

PMP equals the number of planned maintenance hours divided by the number of total maintenance hours multiplied by 100

For example, if you spent 175 hours during the month on planned maintenance and 200 hours on all maintenance, your planned maintenance percentage would be 87.5%.

Planned maintenance is any maintenance that is organized, documented, and scheduled before asset failure. Any maintenance that is scheduled in response to a breakdown is not considered planned maintenance.

Organizations with best-in-class maintenance will have a PMP of 85% or higher. Planned maintenance can also be broken down into several types. Top performing organizations complete about 30% usage-based maintenance, 50% condition-based maintenance, and 5% run to failure maintenance.

How is PMP used?

Planned maintenance percentage is used to make data-driven decisions on maintenance schedules, the allocation of resources, and maintenance processes. Because planned maintenance has a huge impact on the health of assets and how maintenance teams operate, tracking and improving PMP can help organizations maximize asset reliability and control the costs associated with that goal.

What does PMP mean for maintenance?

Planned maintenance is a cornerstone of a healthy maintenance operation. It is central to using time efficiently, reducing downtime, staying compliant with safety regulations, and spending money effectively. Measuring planned maintenance percentage allows maintenance teams to gain insight into all these areas so they can continue to improve on their strengths while targeting their weaknesses.

Create effective schedules

Schedules can be set up and optimized well in advance when a higher percentage of work is planned. This cuts down on wasted labour and parts while allowing the maintenance team to coordinate its tasks with the production schedule.

Reduce downtime

Planned maintenance often takes the form of preventive maintenance, which has been shown to cut down on unplanned downtime by up to 18%. Measuring PMP, along with other maintenance metrics, like MTBF and MTTR, allows you to see which assets cause the most downtime and if it could be remedied with more preventive maintenance.

Stay compliant

Audits come in many shapes and sizes, but they all rely on two basic components: Real-time observation and historical proof. Using planned maintenance percentage is a key way the maintenance team can ensure assets are routinely checked and that there is a comprehensive log that shows these efforts. Both are integral for passing audits and staying compliant.

Control costs

PMP can be used to control costs in two ways— resource efficiency and downtime reduction. A higher PMP means an increase in planned tasks, and the ability to schedule labour and parts far into the future. This helps to reduce instances of over-scheduling and over-purchasing, saving you money. Reducing downtime with planned maintenance leads to more uptime, increased production, and less money lost from stoppages.

The bottom line on planned maintenance percentage

Measuring, analyzing, and improving planned maintenance percentage can have a huge domino effect on your entire facility. Moving away from reactive maintenance to a proactive approach gives your operation more control over its tasks, resources, and money. It also gives critical equipment the attention it deserves and benefits every part of the business, from production to customer service, finance, and beyond.

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