Selecting the Right Key Performance Indicators

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    Selecting the Right Key Performance Indicators

    An effective set of interlocking indicators provides feedback to individuals, groups, and the

    enterprise, directing the behavior of all.

    By Anthony McNeeney, Meridium

    Measures of performance have been used by management for centuries to review current operationalcapabilities. Such measures have been used to assess both departmental and corporate performance, as

    well as trend performance achieved against plan.

    In many industrial facilities, these measurements are related to safety (number of incidents), environmental

    (number of releases), costs (percentage of departmental budgets used), and production (comparison of

    actual vs targeted production output). These measures are needed in order to determine not only if

    resources and costs have been managed for the production achieved, but also whether the assets or plant

    remain in good health. Clearly, these measures provide assurance that asset policies in place today do not

    limit capabilities for tomorrow.

    In order to define a complete set of performance measures, companies must ensure that simple, workablemeasures are in place. The real challenge is not only to select those indicators that satisfy budgetary goals,

    but also to build the activities needed to meet the levels of asset performance required to meet strategic

    goals.

    Selecting the right measures is vital for effectiveness. Even more importantly, the metrics must be built into a

    performance measurement system that allows individuals and groups to understand how their behaviors and

    activities are fulfilling the overall corporate goals.

    BUILDING AND TESTING PERFORMANCE INDICATORS

    As with many management issues, it is often best to build a solution in stages. Suggested stages for

    performance indicators are:

    1. Define the links between corporate goals and major operational perspectives.

    2. Map these strategic links to required processes in each perspective area.

    3. Define a set of near-term and medium-term metrics which drive the new outcomes in each perspective.

    4. Define the gaps and dependencies across the organization which will need to be bridged to result in

    corporate success.

    5. Implement the metrics as individual and group scorecards and monitor to secure the strategic results.

    Use the SMART test

    S = Specific: clear and focused to avoid misinterpretation.

    M = Measurable: can be quantified and compared to other data.

    A = Attainable: achievable, reasonable, and credible under conditions expected.

    R = Realistic: fits into the organization's constraints and is cost effective.

    T = Timely: doable within the time frame given.

    Key performance indicators should be trendable, observable, reliable, measurable, and specific.

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    PERFORMANCE INDICATORS FOR MANAGING RISK AND IMPROVING

    PROFITABILITY

    High level goal: Manage Risk and Improve Profitability of Chemical Plant

    Operations Perspective Reliability Perspective Work Management

    Perspective

    Safety and

    Environmental

    Perspective

    Goals: Reduce operating

    costs and risks;

    maximize output

    Goals: Maximize uptime;

    preserve plant and asset

    integrity

    Goals: Minimize

    corrective work; restore

    asset condition

    Goals: Controlled,

    audited environmental;

    safe, audited operational

    capabilities

    Strategic KPI

    Plant availability

    Number LPO events

    Time operatingoutside

    deterioration

    limits, percent

    Plant uptime, percent

    Production

    targetcompliance

    Strategic KPI

    Plant availability

    Proactive work

    orders, percent

    Emergency work

    orders on high critical

    systems, percent

    Significant

    deterioration

    mechanisms

    improvements

    Inspection compliance

    Protective device

    schedule compliance

    Quantified reliability

    target, number

    Predictive

    maintenancecompliance

    Strategic KPI

    Planning compliance

    Work order complete

    (within 20 percent

    of planned costs)

    Proactive work orders,

    percent

    Scheduling compliance

    Assessments of work

    order complete,

    number

    Quantified availability

    targets, number

    Strategic KPI

    Incident rate

    Safety performance

    index

    PHA/reviews completed,

    number

    PSM compliance audits,

    number

    Significant

    environmental aspects

    defined/quantified,

    number

    Operational KPI

    Process availability

    variance

    Utility variance

    Product transfer

    indicator

    Quality limit

    excursions, number

    Actual counter

    measures, number Startup indicators

    Shutdown indicators

    Offspec product

    Scrap value

    Inventory

    Operational KPI

    MTBF by equipment

    type, area

    MTBR by equipment

    type, area

    MTBM by equipment

    type, area

    MTBF growth

    Cumulative

    nonavailability ofcritical assets

    Unscheduled

    maintenance events,

    number

    Completed work

    order records on

    significant failures,

    Operational KPI

    Emergency work

    orders, percent

    Reactive work

    orders, percent

    Backlog work

    orders, number

    Overtime hours,

    percent

    Work ordersplanned, number

    Cumulative

    maintenance costs

    for standing order

    Average direct cost

    per maintenance event

    Work orders

    Operational KPI

    Outstanding items

    from monthly safety

    inspection report,

    number

    E&S A incidents,

    number

    E&S B incidents,

    number

    E&S C incidents,number

    Total days lost days

    due to injury

    PHA action items

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    number

    Bad actor count

    Current mechanical

    availability

    Mechanical availability

    trend

    scheduled, number

    Rework, percent

    Closed work orders

    within 2 days of

    schedule, percent