Introduction
In the fast-paced world of maintenance management, organizations strive for efficiency and reliability in their operations. However, many face the daunting challenge of unexpected equipment failures that lead to downtime, lost productivity, and increased costs. To mitigate these issues, businesses turn to Computerized Maintenance Management Systems (CMMS). Among the key performance indicators that these systems provide are Mean Time to Repair (MTTR) and Mean Time Between Failures (MTBF). Understanding how to calculate these metrics is crucial for enhancing operational efficiency and extending the lifespan of equipment.
The Importance of MTTR and MTBF
What is MTTR?
Mean Time to Repair (MTTR) is a critical metric that measures the average time taken to repair a failed asset. It reflects the downtime associated with equipment failures and provides insights into the efficiency of maintenance operations. High MTTR values indicate potential risks in operational workflows, signaling a need for improvement in repair processes.
MTTR encompasses various aspects, including troubleshooting and fixing equipment issues. This metric is sometimes referred to by different names, such as mean time to recovery or mean time to resolution, but it fundamentally represents the same concept of downtime.
What is MTBF?
Mean Time Between Failures (MTBF) measures the average time that equipment operates between failures. This metric is critical for understanding equipment reliability and efficiency, as it indicates how long a system is expected to run before experiencing another failure. MTBF is calculated by factoring in the total lifespan of equipment, excluding the time spent on repairs.
A higher MTBF signifies better reliability, suggesting that equipment is less likely to fail frequently. However, it’s important to remember that even equipment with a high MTBF can experience breakdowns due to factors like wear and tear or environmental conditions.
Key Differences Between MTTR and MTBF
1. Meaning
The fundamental distinction between MTTR and MTBF lies in what they measure: MTTR focuses on downtime, while MTBF emphasizes uptime. MTBF assesses the average time between two fixable failures, capturing the total lifespan of equipment in operation. In contrast, MTTR measures the time required to troubleshoot and fix failures, providing insight into the effectiveness of repair efforts.
2. Scope of Calculation
MTBF includes all operational time except for downtime caused by repairs, making it a comprehensive measure of equipment availability.
MTTR calculates only the time taken to repair failed assets, reflecting the efficiency of maintenance processes.
Prerequisite to calculate MTTR and MTBF values in Fogwing CMMS
Entering Total Available Time: While entering asset details, users must specify the Total Available Time in a Day.
This value is crucial for MTBF calculations: Manager / Admin should enter the total hours the asset is expected to be operational each day (e.g., 16 or 24 hours).
If no value is entered, the system defaults to 24 hours. This ensures that MTBF calculations can proceed without missing data.
Downtime Start and End Dates: Maintenance team should specify the exact time when the machine went fault (downtime start) and enter when repairs are completed (downtime end).
Steps to Calculate MTTR and MTBF in Fogwing CMMS
Creating a Work order with work order type as Fault
When a fault is detected, maintenance team creates a Work order with Fault Work Order type in Fogwing CMMS. The system automatically logs the creation time of the Fault Work Order. This timestamp serves as the starting point for the MTTR and MTBF calculation.
Calculation of MTTR and MTBF
MTTR Calculation: Once the Fault Work Order is closed, the MTTR can be calculated automatically within the fogwing CMMS based on the time difference between the work order creation and closure.
MTTR = Total Downtime/No of repairs.
Total downtime: As per the downtime start and end recorded against each "fault" type work order.
No of repairs : As per the number of 'fault' type work order completed.
MTBF Calculation: The MTBF is calculated using the Total Available Time and the number of failures within a specified timeframe. The system uses the Total Available Time input to determine the operational time for the asset.
MTBF= Total Available Time/No of repairs
Total Available Time: the total available time is calculated from the time of asset created in the system and till today as per 'total available time in day' entry.
No of repairs: As per the number of 'fault' type work order completed.
Example of MTTR and MTBF Calculation in Fogwing CMMS
If anyone creates a 'fault' type work order or MRO request and enters the downtime start date. If the start date is not provided, the system will default to the time and date when the fault type work order is created.
The maintenance team executes the fault type work order and records the downtime end date before closing the work order.
Finally, the team checks the MTTR and MTBF values in Asset 360.
Accessing MTTR and MTBF Values in Fogwing CMMS
Asset 360: MTTR and MTBF are visible in the Reliability section, providing an overview of asset performance.
Reports Section: Detailed reports on asset reliability include MTTR and MTBF values, helping users analyze trends and performance.
Metrics Section: Users can find MTTR and MTBF values for individual assets, offering insights into specific equipment reliability.
Conclusion
By following these steps in the Fogwing CMMS, you can effectively calculate MTTR and MTBF, gaining valuable insights into your asset performance. Regularly monitoring these metrics will empower you to make informed decisions and optimize your asset management practices.
If you have any further questions or need assistance, feel free to reach out to us write to our support team at [email protected].