{"id":7394,"date":"2019-02-14T08:14:54","date_gmt":"2019-02-14T16:14:54","guid":{"rendered":"https:\/\/blog-prod.qad.com\/blog\/?p=7394"},"modified":"2021-11-29T15:16:33","modified_gmt":"2021-11-29T23:16:33","slug":"metrics-that-matter-asset-utilization","status":"publish","type":"post","link":"https:\/\/www.qad.com\/blog\/2019\/02\/metrics-that-matter-asset-utilization","title":{"rendered":"Metrics that Matter: Asset Utilization"},"content":{"rendered":"<p>[vc_row][vc_column][vc_single_image image=&#8221;7395&#8243; img_size=&#8221;full&#8221;][vc_column_text]<span style=\"font-weight: 400;\">To ensure the best possible ROI, it\u2019s important to ensure that fixed assets are used productively as much as possible. High utilization is especially important for asset-intensive industries, though companies should never try to achieve high asset utilization by generating unnecessary inventory.<\/span><\/p>\n<h2>What is Asset Utilization?<\/h2>\n<p><span style=\"font-weight: 400;\">Asset utilization is a measure of the actual use of an asset divided by the number of assets available to use. For example, if a machine runs three shifts, its theoretical available use is 24 hours. The actual use will almost always be less than the potential use due to operator breaks and rest periods, setups, adjustments, maintenance, downtime and many other everyday occurrences.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Four key metrics measure asset utilization:<\/span><\/p>\n<ul>\n<li><b>Production Yield: <\/b><span style=\"font-weight: 400;\">The number of usable units from a process calculated as the number of units finished divided by the number of units started.<br \/>\n<\/span><\/li>\n<li><b>Overall Equipment Effectiveness (OEE): <\/b><span style=\"font-weight: 400;\">A compound metric that provides a view of current efficiency for a machine, line or cell. This metric considers the work center\u2019s availability, its output and the quality of output. It is calculated as: <\/span><\/li>\n<\/ul>\n<p style=\"text-align: center;\"><b>(Availability x Performance x Quality)<\/b><span style=\"font-weight: 400;\"><br \/>\n<\/span><\/p>\n<ul>\n<li style=\"list-style-type: none;\">\n<ul>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Availability = (operating time divided by planned production time) x 100<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Performance = ({total pieces divided by operating time} \/ ideal run rate) x 100<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Quality = (good pieces divided by total pieces produced) x 100<\/span><\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<ul>\n<li style=\"font-weight: 400;\"><b>Unplanned Downtime: <\/b><span style=\"font-weight: 400;\">Any time an asset is scheduled for production but is not operating. Reasons might include emergency or unplanned maintenance, setup, repair, parts shortages or stockouts. It is calculated as: <\/span><\/li>\n<\/ul>\n<p style=\"text-align: center;\"><b>({All Downtime \u2013 Planned Downtime} divided by Total Time Available)<\/b><\/p>\n<ul>\n<li style=\"font-weight: 400;\"><b>Maintenance Spend: <\/b><span style=\"font-weight: 400;\">The ratio of<\/span> <span style=\"font-weight: 400;\">the total cost of maintenance (labor and materials) divided by the total cost of goods sold.<\/span><\/li>\n<\/ul>\n<h2><span style=\"font-weight: 400;\">Production Yield<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Monitoring yield is critical to ensuring schedule accuracy and that there will be sufficient units available to meet customer demand. For example, if a product has an 80 percent yield and a customer orders 100, planners know to schedule 125 units to ensure that 100 good units will finish the process. That ensures that adequate material will be available to account for the units that will fail to meet spec and that adequate time is scheduled to complete the entire batch of units. <\/span><\/p>\n<p><span style=\"font-weight: 400;\">If yield is unknown, planners might schedule the required 100, and the customer order would be short shipped, leading to an unhappy customer. MRP calculations also would neglect to buy adequate raw materials to complete the units, leading to unplanned downtime.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Best practices for managing yield include regular preventative maintenance to ensure equipment operates properly, managing tooling to ensure that the right tools are ready and available and master data accuracy to ensure that yields are up-to-date.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Overall Equipment Effectiveness<\/span><\/h2>\n<p><span style=\"font-weight: 400;\"><a target=\"_blank\" href=\"https:\/\/www.qad.com\/blog\/2019\/09\/actionable-insights-oee-action-center-overview\" rel=\"noopener\">Overall Equipment Effectiveness (OEE)<\/a> can provide a complete picture of operational effectiveness, but it makes sense to drill down into the component calculations used to calculate OEE to find the source of any worsening trends. <\/span><\/p>\n<p><span style=\"font-weight: 400;\">OEE can point to poor maintenance programs, poor performance or inadequate maintenance, repair and overhaul (MRO) management so that required maintenance components are unavailable when needed. It can also help to track mean time between failures to improve the preventative maintenance (PM) scheduling process. Integrating the PM schedule with the production schedule helps to ensure that PMs are completed on time, which will improve equipment performance and longevity.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Third-party enterprise asset management (EAM) solutions are usually unable to integrate directly with an ERP solution\u2019s production scheduling, so they require cumbersome and expensive workarounds.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Unplanned Downtime<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Monitoring unplanned downtime helps clarify the efficacy of a company\u2019s preventive maintenance program. When the program is ineffective or not rigorously adhered to, unplanned downtime will increase because equipment will frequently fail unexpectedly.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Unplanned downtime can also point out concerns about tooling maintenance, inventory management processes and the skills or availability of the setup crew.<\/span><\/p>\n<p><a href=\"https:\/\/www.qad.com\/solutions\/manufacturing-erp\/data-sheet\/qad-cloud-qms\"><span style=\"font-weight: 400;\">QAD QMS<\/span><\/a><span style=\"font-weight: 400;\"> includes training management to help ensure that the setup team has it right the first time. Inventory management, including MRO planning in QAD EAM, can ensure that maintenance parts are available as needed.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Maintenance Spend<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Monitoring this metric can help show when it may be time to retire older assets and replace them with newer, more efficient equipment. As the ratio of maintenance spend to cost of goods sold (COGS) gets higher, the equipment begins contributing disproportionately to the product cost.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Additional Possible Metrics<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Some companies like to track two additional metrics: <\/span><b>Planned Downtime<\/b><span style=\"font-weight: 400;\"> and <\/span><b>Maintenance Cost to Asset Value<\/b><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Planned Downtime can show the company if the PM program is taking up a lot of time or not. Comparing the planned downtime and the mean time between failure (MTBF) for equipment can help to pinpoint whether the PM program is better than it needs to be.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Maintenance Cost to Asset Value can shed light on a similar problem. When the cost of a machine\u2019s annual maintenance exceeds a specified threshold of its remaining book value, it may be time to retire the asset in favor of a newer, more efficient piece of equipment. It is also possible that this metric identifies a rigorous preventative maintenance program, so it should be used in conjunction with other metrics like unplanned downtime, OEE and MTBF before making the decision to replace equipment.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In QAD\u2019s Cloud ERP, these metrics can be tracked and managed using the Action Centers: <\/span><a href=\"https:\/\/documentlibrary.qad.com\/help\/webui\/sanmiguel\/en-US\/QAD%20Online%20Help\/PredefinedACMaintenanceManager.html#wwID0EFEFO\"><span style=\"font-weight: 400;\">Operations Action Center<\/span><\/a><span style=\"font-weight: 400;\">, <\/span><a href=\"https:\/\/documentlibrary.qad.com\/help\/webui\/sanmiguel\/en-US\/QAD%20Online%20Help\/PredefinedACMaintenanceManager.html#wwID0EGHHO\"><span style=\"font-weight: 400;\">Maintenance Manager Action Center<\/span><\/a><span style=\"font-weight: 400;\"> or using <\/span><a href=\"https:\/\/www.qad.com\/solutions\/manufacturing-erp\/data-sheet\/qad-enterprise-asset-management\"><span style=\"font-weight: 400;\">QAD EAM<\/span><\/a><span style=\"font-weight: 400;\">. Legacy QAD solutions for tracking metrics include: <\/span><span style=\"font-weight: 400;\">QAD Business Intelligence<\/span><span style=\"font-weight: 400;\"> and <\/span><span style=\"font-weight: 400;\">QAD Operational Metrics<\/span><span style=\"font-weight: 400;\">.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Best Practices for Equipment Utilization<\/span><\/h2>\n<ul>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Use a Corrective and Preventive Action (CAPA) solution to systematically investigate failures<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Integrate electronic communication networks (ECNs) into production in a way that meets customer safety and usability needs without undue production disruption<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Use integrated preventive maintenance scheduling to ensure that PMs are considered in promise dates and scheduling<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Calculate yields and use them in planning and scheduling<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Track MTBF to ensure that equipment is operating at its peak and not being over-serviced<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Implement effective MRO and spares management<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Develop and adhere to a reasonable preventive maintenance program that supports the manufacturer\u2019s recommendations<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Train set up crews in rapid changeover techniques<\/span><\/li>\n<li style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Implement a tooling management and maintenance program<\/span><\/li>\n<\/ul>\n<h2><span style=\"font-weight: 400;\">Choosing Metrics<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">When operations run smoothly, planners can minimize excess inventory and ensure that customer deliveries happen on time. Much of scheduling success depends on ensuring that machinery and equipment function efficiently and operate on a reliable schedule. This requires an effective preventive maintenance program and careful monitoring of the trend for asset utilization.<\/span><\/p>\n<p><i><span style=\"font-weight: 400;\">What challenges are you finding most significant when it comes to asset utilization? Let us know in the comments section below.<\/span><\/i>[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][\/vc_column][\/vc_row]<\/p>\n","protected":false},"excerpt":{"rendered":"<p>[vc_row][vc_column][vc_single_image image=&#8221;7395&#8243; img_size=&#8221;full&#8221;][vc_column_text]To ensure the best possible ROI, it\u2019s important to ensure that fixed assets are used productively as much as possible. High utilization is especially important for asset-intensive industries, though companies should never try to achieve high asset utilization by generating unnecessary inventory. What is Asset Utilization? Asset utilization is a measure of the [&hellip;]<\/p>\n","protected":false},"author":13,"featured_media":7395,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[182,199],"tags":[681,687,685,264,683,686,682,574,542,684],"class_list":["post-7394","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-featured","category-manufacturing-trends","tag-asset-utilization","tag-maintenance-cost-to-asset-value","tag-maintenance-spend","tag-metrics","tag-overall-equipment-effectiveness","tag-planned-downtime","tag-production-yield","tag-qad-business-intelligence","tag-qad-operational-metrics","tag-unplanned-downtime"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Metrics that Matter: Asset Utilization | QAD Blog<\/title>\n<meta name=\"description\" content=\"What is asset utilization? 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