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Factories participating in MICA Ratios over the last six years have reported numerous direct and indirect benefits from the exercise. These have included substantial savings triggered by opportunities identified in the comparison process, significant improvements in organisation and work planning, better staff focus, especially at supervisor level and the ability to clearly demonstrate a professional approach to the management of factory maintenance.
In some cases, clients have adopted the MICA Ratios as part of their annual reporting framework. |
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£1M Saving
For one large pharmaceutical factory in Ireland the first application of ratios analysis and benchmarking showed that their overall maintenance spend was significantly above the norm for a group of very similar factories. When they saw these results, management carried out a cost reducing exercise that cut their annual maintenance spend by approximately £1M a year. Ratios benchmarking may not have told them how to save the money, but it did tell them there was potential to do so – something that they were not aware of until they saw how their results compared with other factories.
As a consequence, this factory and others compare their results every year to make sure that they are achieving a performance that is at least as good as others in their industry and, if they can do it, get results that are better than most or all of their comparison group. |
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Unplanned Maintenance
In some cases, just looking at the numbers is enough to trigger positive change. One company recorded the level of unplanned maintenance work for the first time as part of participating in our ratios benchmarking exercise. Once they saw the results (80% unplanned, reactive work) they knew they had a serious problem to solve.
Within two years they had turned this situation around, achieving less than 20% unplanned work and boosting both efficiency and customer satisfaction substantially.
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