Industrial maintenance optimization : mastering MTTR to reduce costs

Maintenance management is critical in industrial settings as it plays a key role in cost reduction and operational efficiency. Key metrics like MTBF (Mean Time Between Failures) and MTTR (Mean Time to Repair) provide valuable insights into equipment reliability and maintenance performance.

Costs associated with maintenance typically include surprise repairs of equipment or operational downtime due to equipment failure. MTTR is a particularly important indicator in this context.

What is MTTR?

Definition and Context

MTTR, or Mean Time to Repair, measures the efficiency of an organization’s maintenance team response. It assists organizations in minimizing operational downtime through constant monitoring, enriched by system feedback. By reducing downtime, an organization’s operational uptime and productivity are concurrently increased. The savings achieved by decreasing downtime are significant. Maintenance service efficiency is enhanced by sustaining proper equipment upkeep and rigorous control. Additionally, the adoption of predictive maintenance within your organization will improve operations through continuous monitoring of variables within established limits.

The formula for calculating MTTR is as follows:

MTTR = total maintenance time / number of repairs.

While the basic formula is simple, its diligent and attentive application can lead to long-term improvements. It is crucial for the team to have proper training to handle equipment and utilize maintenance software.

Differences between MTTR, MTBF, and MTTA

• MTBF (Mean Time Between Failures). A system is considered reliable when the time between failures is lengthy, thus increasing confidence in the equipment.
• MTTA (Mean Time To Assistance). This represents the average time from detecting a failure until the start of repair.
• MTTR (Mean Time To Repair). MTTR is split into four different contexts: Mean Time to Repair, Mean Time to Recovery, Mean Time to Respond, and Mean Time to Resolve. Each of these aspects corresponds to an average time to repair the equipment, for its recovery, for the response, and for problem resolution.

How do these indicators complement each other?

All these maintenance indicators are interdependent as they are based on time. Response times are essential since time is a key element in all calculations. These indicators provide an overall view of the system’s efficiency and performance, facilitating decisions for optimal maintenance.

 

Calculating MTTR

Formula and Calculation

MTTR is calculated by dividing the total maintenance time by the number of repairs, thus giving the average time per repair. For example, if 30 hours of unplanned maintenance were needed for equipment that experienced 9 breakdowns over the year, the average repair time would be 3.33 hours. An average time of less than 5 hours is generally considered satisfactory in the industry, though this depends on many factors such as type of equipment, its criticality, and operational time.

Significance of MTTR in Maintenance Management

A low MTTR is crucial for a swift response. It is imperative to take immediate action in the event of a failure, requiring highly skilled personnel for repairs. Regular maintenance of equipment extends the time between failures, reducing recovery time and helping to maintain a stable MTTR, which in turn lowers costs.

Digital Tools for MTTR Management

Using a CMMS (computerized maintenance management system) offers multiple advantages, such as automation of calculations, real-time monitoring, and the prediction and prevention of failures, contributing to efficient operation and a stable MTTR.

In summary, MTTR is a key indicator for effective and precise decision-making in the event of a failure. Through careful monitoring and tracking, it is possible to optimize the repair process and identify areas of improvement, thereby reinforcing the operational efficiency of the business.

To reduce the frequency of incidents with your assets, consider implementing a CMMS. DimoMaint offers comprehensive maintenance solutions to maximize the efficiency of your operations.