The reports and indicators that actually reduce failures.
MTBF, MTTR, MTTF, PM compliance and Pareto analysis are not decoration. They are how you find out which interval is wrong and which machine is quietly eating the budget.
The core indicators
MTBF
Mean time between failures, per machine. Rising MTBF is the clearest single sign your preventive plan is working.
MTTR
Mean time to repair. Falling MTTR usually means the standard activities, spare parts and technical archive are in place.
MTTF
Mean time to failure, for components that are replaced rather than repaired.
PM compliance
The percentage of planned activities actually completed on time — the honest measure of whether the plan is real.
Failure and downtime analysis
Pareto of worst offenders
The equipment causing the most failures, ranked. Usually a small minority of machines accounts for most of your lost hours.
Repeat failures
The same failure mode recurring on the same asset is the strongest evidence that the corrective action never addressed the root cause.
Failure causes
Standardised causes recorded on every work order, so the analysis is comparable rather than free text.
Longest downtime
Equipment ranked by total stoppage hours, which is often a different list from the one ranked by failure count.
Cost and workforce reporting
Spare part cost
Consumption and spend per part and per machine, over any period — the basis for deciding what to stock.
Man-hour cost
Labour cost by person, crew and equipment, so the true cost of keeping a line running is visible.
Contractor cost
Outsourced repair spend tracked against the same equipment records as internal work.
PM vs EM share
The ratio of planned to emergency work. Moving this ratio is the single clearest goal of a maintenance programme.
Reports are only as good as the work order behind them
Every one of these indicators is computed from what technicians recorded when they closed the job: the time taken, who did it, what was replaced, what the failure was and what caused it. If that reporting is thin, the KPIs are decorative.
This is why standardising failure modes and causes per equipment family matters more than it sounds. Free-text descriptions cannot be aggregated. A fixed list can, which is what turns a year of work orders into an argument for changing an interval.
Want to see these on your own data?
Send us a sample of your failure history and we will show you the reports it would produce.
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