Wrench time is defined as that portion of a craftsman’s day that is actually spent affecting the assets in a positive way. In its simplest form, this means a wrench is on the equipment. Most estimates place this percentage of time in the 20-30% range, with top performers often considered as those who operate in the 50-55% range.
Even among the best organizations, at least 45% of the time is lost to non-wrench time activities such as travel time, trips to the warehouse, waiting for instructions, waiting for equipment, etc. We will never completely eliminate these activities, but with discipline, we can shrink them and bring our performance into the 50% range.
For that, here are our methods:
Spare parts are the lifeblood of operational reliability and plant capacity. No plant can operate at a high level of output without a reliable supply of functional spare parts. Spare parts form the bedrock on which operational reliability is built. Therefor appropriate storage, treatment of, and timely access to the required parts is indispensable. Yet, spare parts are also the most overlooked contributor to reliability outcomes.
One of the main concern of efficient companies is to manage the knowledge in order to transfer it from experienced technicians to new comers. This is especially true with topics such as Lock Out Tag Out actions, advanced overhauling or pressurised equipment maintenance.
The Equipment Maintenance Plan, or EMP, not only identifies the specific tasks necessary to minimize failure mode consequences, but it also contains information that guides work order scheduling and provides pertinent information for budgeting maintenance resources and communicating downtime requirements to operations.