At the end of month we have generated maintenance cost report but does not accuracy because some cost such as external service do not charge in work order on time, it posted after work done and payment condition 30days due date.

How do I tracking the actual maintenance cost in the real time at the end of month?

Generate the report after two months !!

Split your jobs in different types, let say PM jobs will not vary much.
Obviously Management wants to see the costs of the big jobs, there is no chalenge in reporting : we did 100 pm jobs at the costs of $10 each etc.. figure out an average, and check if you are not deviating too much, let say a 20% variance.

The big jobs are the eye catchers, especially if your manager has "reluctantly" authorized "big" expenses and have to explain to his boss why he is spending company resources like santa-claus. Shutdowns planned x unplanned, overtime, avoidance costs, rush orders with the vendors trippling their normal prices, an asset that breaks down every week, are interesting cases and create opportunities for improvement.

I think we can get and report total maintenance cost in 2 ways:
1) from maintenance cost centres in accounting module ie planned vs actual
2) from summation of all work order costs in which you have estimated, planned or actual costs.

Now I think you have problems with the actual work order costs which are charged from accounting module to the work orders. That's why work orders should be filled up immediately after work completion. Otherwise it's not suitable to report maintenance cost for short periods like monthly. However, the work order costs are ideal for long term cost analyses eg lifecycle cost for equipment or annual actual maintenance costs.

Steven and Josh

I agree with you about summary the cost report after 2-3 months, but my KPI should have the cost for measure maintenance cost per product(ton) in monthly basis. I've discuss the problem with some personnel(CO module) to carry out my problem, she said the same first way of Josh suggest.

Kick out the KPI!!

If you cannot comply with it why you should punish yourself!!
At the end you will be hold acountable for a "stupid" KPI

That's ok Steven, I'll tell my top management that's you suggest me....thank you

This is an example of a "get the boss off my back" situation: having to spend time dealing with some KPI that are not "Key" anymore or simply "stupid", rather than analyzing a problem, training a recently promoted planner, etc.

Maybe you should offer them to participate in the forum , lets hear the story from their point of view!!

Eugene, maybe our bosses are already watching us

Aromatics, you problem sounds more complicated than the normal scenario that we thought.

Now how to get maintenance cost per ton product when the complex produces multiple products? This is more challenging than a simple one product plant.

How many products does your complex produce?

Here is what I think as a way forward:
Have you set up the maintenance cost centres according to plant areas which correspond to each product line. You need to consult CO to get this fixed if not done yet.

So all work order cost should be charged to these product-based cost centres which in turn are rolled up to your Central Maintenance cost centre.

Josh, I've daily totally product ton from production department, if we want to know how many maintenance cost per product ton in WC(Aromatics process). It's not necessary?

The reason why to develop more information for top management because i'm the maintenance information manager.....Thank you

Ok, so you have one product only per the aromatics complex. In that case, it's simple.

Get the total monthly actual maint cost from CO and divide by the monthly production in tonnes. Beware to look at trending of the maint cost per ton aromatics product, not the absolute figure becasue some payments are charged to work orders late. Otherwise give the planned maint cost per metric ton product as well.

Panuphan, my advise is to aquire the book:
Developing Performance Indicators for Managing Maintenance written by "maintenance blackbelt" Terry Wireman.

Some of the "KPIs" developped by "beanies" are simply impossible, but that is not always their fault, the technical side of business can be quite complex too

quote:

Originally posted by svanels:
Eugene, maybe our bosses are already watching us

Can't be true, our lives would be much easier !

Steven, I've already this book and found some measure in financial indicators level that is maintenance cost per produced but I desired maintenance cost per product ton only.

I mistake?

We monitor maint cost per ton product. This KPI originates from Dupont if not mistaken. At company level, we monitor prod cost per ton product. It's far from beancounting.