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MECANO is a tool used in the performance management which permits to calculate a complete maintenance indicators catalog.


  • The book is divided in 3 families which are fully covering the maintenance management.

  • The indicators calculation is automatic (based on SAP) and adaptable to the different Solvay sites.

  • The indicators are mainly based on the SolmaX process.

 


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Strategic Indicators:

This list provides information about long term processes. The frequency of calculation is at least monthly and in the majority of the cases is yearly. It allows maintenance managers and direction teams to take medium and long term decisions.

 

Maintenance Efficiency:

This list provides all the information related to the maintenance process efficiency “do the things right”. After a SolWOM transformation it would allow the site to follow their improvement and also to locate improvement possibilities.

Maintenance Effectiveness:

This list provides all the information related to the maintenance process effectiveness “do the right things”.After a ReSol√ transformation it would allow the site to follow their improvement and also to locate improvement possibilities.


1.1Maintenance costs per ton of good production
1.2Direct impact of maintenance on industrial performance / impact of OEE losses CAT. 2 and 4
1.3Maintenance costs versus replacement asset value
1.4Structure of maintenance costs
1.5Portion of Solvay maintenance headcount versus Solvay plant headcount
1.6Structure of maintenance labor
1.7Cost by type of activity
1.8Importance of MRO (spare parts)
1.9Emergency or urgent work
1.10Expend versus budget
1.11Capex investments



Gatekeeping2.1Created notifications by priority
2.2Number of notifications without assigned work order
Planning2.3Portfolio of work orders by status
2.4Planned work (backlog)
2.5Delayed notifications by type
Scheduling2.6Weekly scheduled compliance
2.7Break in works
2.8Available weekly scheduled ressources
2.9Unscheduling rate by causes
2.13Daily Scheduled Compliance & Reactive Work
Execution2.10Wrench time
2.11Respect of bar code confirmation rate
2.12Respect of notification date
2.14Backlog in Number of Weeks



3.1OEE losses
3.2Respect of maintenance plan
3.3Number of WO per equipment
3.4Number of Problem Solving Sessions and impact
3.5Number of FMECA and impact

1.     What is a KPI

 

A KPI : Key Performance Indicator permit managers to have relevant statistics to follow their progression in their work on different time scales. This is also a communicating tool to motivate and share with the whole team.

KPI don’t have the same definition and their particularities are their :

-          Frequency of statement (yearly / monthly / weekly / dayly / ...)

-          Priority (POC / 1 / 2)

-          Units (nb of WO / man x day / % / ...)

-          Process step (gate-keeping / planning / Scheduling / Executiong)

 

Manufacturing Excellence team has already worked with different sites in order to build a list of maintenance indicators. The objective of manufacturing excellence is to create a standard solution adapted for all the different Solvay sites.

A list of indicators has been created in collaboration with several Solvay sites. That list contains all the necessary indicators to manage the performance of plant maintenance process

Maintenance indicators list have been created using three different levels, adapted to SolmaX maintenance process.

 

 

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