CMRP key terms

A composite metric multiplying availability, performance, and quality rates to show how much of the theoretically possible good output a machine actually produced. It highlights where losses occur.

The six categories of equipment loss: breakdowns, setup and adjustment, idling and minor stops, reduced speed, process defects, and startup rejects. They map to availability, performance, and quality components of OEE.

The average operating time between consecutive failures of a repairable asset, calculated as total run time divided by number of failures. It measures reliability and supports interval decisions.

The average elapsed time needed to restore an asset to working condition after a failure, including diagnosis, parts, and testing. It measures maintainability rather than reliability.

A structured process that identifies asset functions, failure modes, and consequences, then selects the most cost-effective maintenance strategy for each failure mode. It often favors condition monitoring over fixed intervals.

A team-based method that lists ways a component or process can fail, rates severity, occurrence, and detection, and prioritizes actions by risk priority number. It is proactive and design- or process-focused.

A ranking of assets by the consequence of their failure, considering safety, environment, production impact, and cost. Results guide maintenance resources, spares stocking, and preventive task depth.

Maintenance triggered by measured evidence of degrading condition, such as vibration, temperature, or oil analysis, rather than by calendar or run-hour intervals. It aims to intervene just before functional failure.

A strategy that uses condition data and trend models to forecast when a failure will occur and schedule intervention accordingly. It depends on reliable measurement, baselines, and alarm limits.

The time between the point where a developing failure first becomes detectable and the point where it becomes a functional failure. It sets the maximum useful inspection frequency for condition monitoring.

A condition monitoring technique that interprets machine vibration signatures to detect imbalance, misalignment, bearing defects, and looseness. Trend and frequency data guide fault diagnosis before failure.

Scheduled maintenance tasks performed at fixed intervals or usage thresholds to reduce failure probability. Effectiveness depends on task selection, correct intervals, and compliance with the schedule.

The percentage of scheduled preventive maintenance work orders completed within the defined due window. It measures schedule discipline, not whether the tasks actually prevent failures.

Production time intentionally lost for scheduled maintenance, changeovers, or trials. It is excluded from availability calculations in OEE when properly planned and recorded.

The amount of approved, unfunded work waiting to be scheduled, usually expressed in craft-weeks. It signals whether staffing matches workload; a common target range is two to four weeks.

The formal process for requesting, approving, planning, scheduling, executing, and closing maintenance work. Each order captures labor, parts, and failure data used for analysis and cost control.

The percentage of scheduled work orders completed in the week they were scheduled. It measures how well the organization executes its plan and protects planned work from reactive interruptions.

Planning defines the scope, labor, tools, and parts for a job; scheduling assigns it to a time slot and crew. Separating the two improves craft productivity and reduces delays.

A lean practice in which operators take responsibility for basic cleaning, inspection, lubrication, and minor adjustments on their own equipment. It builds ownership and frees skilled craft for complex work.

A company-wide approach that engages operators and maintenance together to maximize equipment effectiveness through autonomous maintenance, planned maintenance, and continuous loss elimination.

A structured investigation that traces a problem back to its underlying causes rather than its symptoms, often using cause-and-effect diagrams, five whys, or fault trees. It results in verified corrective actions.

A change made to eliminate the cause of a detected problem so it does not recur, as distinct from a repair that only restores function. Effectiveness should be verified after implementation.

An iterative improvement cycle: plan a change, run it on a small scale, check results against expectations, then standardize or adjust. It underpins most continuous improvement programs.

A production philosophy focused on eliminating waste, such as excess inventory, waiting, motion, and defects, while improving flow and value from the customer's perspective.

A workplace organization method: sort, set in order, shine, standardize, and sustain. It creates visible, clean work areas that support safety, quality, and equipment condition.

The use of control charts and process capability measures to distinguish normal variation from special-cause signals. It helps keep processes stable and detect deterioration early.

A measure of whether a stable process can consistently meet specification limits, often expressed as Cp or Cpk. It compares process spread and centering to the tolerance width.

A structured list of the components, quantities, and relationships needed to build a product. In maintenance, an equipment BOM identifies parts for a specific asset.

A stocked part whose absence would cause unacceptable downtime or safety risk and which cannot be quickly obtained elsewhere. Stocking decisions weigh lead time, failure rate, and consequence.

The stock of spare parts, consumables, and materials held to support maintenance and operations. Accuracy of records and cycle counting are essential to avoid stockouts and excess holding cost.

A recurring audit in which a small subset of inventory items is counted on a rotating basis and reconciled to records. It replaces full physical inventories and improves stock accuracy.

A method that breaks a task into steps, identifies hazards at each step, and defines controls before work begins. It is often used to brief craft on high-risk maintenance jobs.

A procedure that isolates hazardous energy sources and applies locks and tags so equipment cannot be started or released during service. Only the person who applied a lock removes it.

A formal written authorization for high-risk activities such as hot work, confined space entry, or line breaking. It documents hazards, controls, and sign-offs before and after the task.

A grid showing each employee's proficiency against required competencies, used to identify gaps and plan training. It supports work assignment and succession planning.

A systematic review that compares required competencies with current capabilities to determine who needs what training. It links development spending to business and safety gaps.

A defined set of knowledge, skills, and behaviors required for a role or job family. It provides the standard against which assessment, hiring, and development are measured.

A quantifiable measure tied to a strategic objective, used to track performance over time. Effective KPIs are few, owned, and paired with targets and review routines.