Industry Benchmark Survey

COMPANY NAME _______________________________ PLANT/FACILITY NAME _________________________________

LOCATION

_______________________________ LOCATION ___________________________________________

_______________________________
___________________________________________
_______________________________
___________________________________________

COMPANY REP.

_______________________________ TELEPHONE NO.___________________ FAX ________________

World Class Maintenance Benchmark Indicators

Indicator
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10
Indicator
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Indicator Description
What is the percent of annual total expense maintenance costs
to annual total plant sales? Total maintenance costs include
shutdown/turnaround annualized allocations.
What is the percent of annual total maintenance costs to plant
replacement asset value (RAV)? RAV is the cost of replacing
current assets.
What is the percent of maintenance stock value to RAV?
What is the RAV value per maintenance employee?
What is the cost per employee based on annual total expense
maintenance cost?
What is the number of maintenance craft personnel per first
line supervisor (company and contract)?
What is the number of maintenance craft personnel per
planner?
What is the number of first line supervisors per planner?
How many organizational levels between plant manager and
maintenance craft personnel?
What percent of critical performance measures have been
achieved?
Indicator Description
Training dollars represent what percent of the maintenance
budget?
What is the number of specific crafts used in routine
maintenance?
What percent of minor maintenance work is accomplished by
production?
What percent of equipment have Preventive Maintenance (PM)
Page 1 of 2

Response

Comments

World Class 1.5% TO 2.0%

World Class 0.5%
World Class > $5,000,000
World Class > $100,000
World Class - 15 to 20
World Class 30 to 60
World Class 2 to 3
World Class 2 to 3
World Class > 90%
Response

Comments
World Class 4% to 5%
World Class 2 to 3
World Class 30% to 40%
World Class 80%

Industry Benchmark Survey

15
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25
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30

tasks been developed for and used?

In maintenance, how many hours is each craft person
scheduled?
What is the percent of completed work orders that have been
planned?
What is the percent of completed work orders that are PM?
What percent of systems have had a full Reliability Centered
Maintenance analysis?
How many weeks of backlog for the total maintenance crew?
What is the percent of completed work orders that are
emergency?
What is the percent of rework by maintenance?
What is the percent of overtime to total maintenance hours
worked?
What is the percent for availability for production systems?
(Use composite rate for multiple production systems).
What are the annual inventory turns for maintenance material
(annual issue dollars divided by average inventory dollars)?
What is the percent of emergency purchase orders?
What is the percent of on-time delivery for purchased goods?
What is the percent of vendor stock to on-hand maintenance
stores stock (by value)?
What is the percent of inventory accuracy of maintenance
spare parts?
What is the percent of maintenance parts stockouts?
What percent of warehouse line items show no issue in the
last three years?

Page 2 of 2

World Class 8 of 8 hrs or 100%

World Class > 95%
World Class 30 to 60
World Class > 20%
World Class 2 to 3 weeks
World Class < 5%
World Class < 5%
World Class - 5% to 8%
World Class 94%
World Class 3 to 4 turns
World Class < 10%
World Class > 90%
World Class > 30%
World Class > 98%
World Class < 5%
World Class < 10%