The document provides instructions for completing a Qwik Ratio Exercise to assess key maintenance metrics at a plant. Users are asked to gather operational data, calculate 10 maintenance-related ratios based on the data, and plot the ratio scores on a radar chart. The chart is designed so that scores closer to 10 indicate world-class performance and lower scores represent improvement opportunities across various maintenance functions.

1. Qwik Ratio Exercise
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2. QWIK RATIO EXERCISE
Directions:
Step 1. Gather the Data
Complete the data table, Page 1 of the exercise.
Note: If you don’t have the data, provide a “best estimate” number.
Step 2. Calculate the Ratios
Using the value in the data table (Page 1), calculate the indicated rations in
each of the 10 boxes on Page 2.
For example, to calculate the first ratio, Maintenance Cost, % ERV, do the arithmetic
in the box:
Line #6 / Line #8
Score your result on a scale of 1-10 based on the scale shown for each ratio.
<2.5% 3.0% >3.5%
Points 10 5 1
Note: If you don’t have the data, even an estimate of the data, and can’t do the calculation
from the data, then at least estimate (or guess) the ratio and score it 1-10 on the scale.
You now should have a 1-10 score in each of the 10 boxes.
Step 3. Plot the Radar Chart (“spider diagram”)
Using the radial scale of 1–10 on the radial graph (page 3), plot each of the 10 box scores
on its corresponding radial line. Connect the points. Color the diagram.
INTERPRETATION
This chart has been designed to plot industrial averages at about 5 points, and “world
class” or “best of class” numbers about 10 on the chart.
That means that to the degree that you are “world class” you will have lots of area under
the curve, most ratios close to 10 (say 7 or better).
To the degree that you have “opportunity” for improvement, your values will be low, and
not much area under the curve (say 0–3); there will be lots of “white” space on the outside
of the curve. See the example plot on Page 4.
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3. QWIK RATIO CHART DATA ELEMENTS
1. How many total man-hours did your maintenance operation use (do not count
contract services or capital projects)? This would be maintenance activities for
effort-hours
the year to include providing service for facilities, equipment, grounds, etc.
2. Of the hours listed above in #1, how many man-hours were dedicated to
Preventive Maintenance activities? PM tasks are planned and scheduled
activities conducted a certain frequencies designed to prolong equipment life
and provide early warning of impending problems, such as cleaning, lubricating, effort-hours
adjusting, inspecting, and minor repair/replacement. Does not include major
repairs or “opportunity” repairs.
6. What were the total maintenance expenditures for your plant (less capital
projects or other ‘non-maintenance’ related costs)? Include the total costs to
maintain facilities and equipment (and grounds, if appropriate) to include labor,
parts, materials, maintenance contractors, etc. Include all maintenance
expenditures for all maintenance departments at your site. $
8. At current prices, how much would it cost to replace you entire facility
(Estimated Replacement Value)? This is the cost of replacing the facility and
$
equipment at today’s prices (less real estate).
10. How many maintenance hourly craftspeople or non exempts, such as
technicians, electricians, mechanics, pipefitters, and millwrights, did you have
working full-time at you plant?
14. How many full-time maintenance planners did you have? Maintenance planners
plan, prepare and sometimes schedule maintenance activities. Planning includes
all activities necessary to ensure the proper parts, tools, and other supplies are
allocated and sequenced for the craftsmen at the start of a job.
15. How many maintenance support personnel did you have working at your plant?
Support personnel include planners, supervisors, maintenance engineers,
maintenance clerical personnel, maintenance managers, maintenance inventory
control personnel, etc.
17. What was your overall average maintenance overtime percentage?
%
18. Of the total maintenance hours listed in questions #1, above, how many hours
of work were formally planned and scheduled in advance of the job versus effort-hours
emergency, crisis, or unscheduled work in general.
19. Of the total maintenance hours listed in question #1, above, how many hours
were ‘captured’ (charged) on a work order.
23. What was your overall inventory turn rate:? (Overall turn rate is generally
calculated as total dollars consumed divided by average dollar inventory value, or
storeroom dollars issued over dollars storeroom value.)
24. What was your average service level? (Service level is generally defined as the
percentage of time stocked parts are available when requested. Or, the number
of issues satisfied divided by the number of issues requested.) %
27. How many total man-hours of formal training did maintenance craftspeople
receive? (Do not include OJT or other informal forms of training.)
effort-hours
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4. QWIK RATIOs
1. Maintenance Cost, % ERV Line #6 / Line #8
<2.5% 3.0% >3.5%
Points 10 5 1
2. Planned Maintenance, % Line #18 / Line #1
>90% 90-75% 74-60% 59-40% <40% 0
Points 10 8 6 4 2 0
3. PM Effort Hours, % Line #2 / Line #1
>50% 34% 25% <10%
Points 10 5 2 0
4. Effort Hours Charged to Work Orders, % Line #19 / Line #1
>90% 89-80% 79-70% 69% 0%
Points 10 8 7 5 0
5. Inventory Turns Line #23
>2.0 1.0 <.5
Points 10 5 0
6. Service Level Line #24
>98% 95% 92% <92%
Points 10 5 2 0
7. Maintenance Overtime, % Line #17
<5% 10% 15% >15%
Points 10 5 2 0
8. MTCE Planners / MTCE Hourly Line #14 / Line #10
1/<25 1/30 1/>35 No Planners
Points 10 5 2 0
9. MTCE Support / MTCE Hourly Line #15 / Line #10
1/<3.5 1/4 1/5 1/>10
Points 10 5 2 0
10. Training Hours / Craftsperson (per yr) Line #27 / Line #10
>100 50 0
Points 10 5 0
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5. QWIK RATIO CHART
10
TRNG 9 ERV
8
7
6
SRATIO 5 PLAN
4
3
2
1
PRATIO PM
OT WO
SERV INV
1 ERV $, % ERV
2 PLAN % PLANNED MAINTENANCE
3 PM % PREVENTIVE MAINTENANCE
4 WO % HRS CHARGED TO WOs
5 INV INVENTORY TURNS
6 SERV INVENTORY SERVICE LEVEL, %
7 OT OVERTIME, %
8 PRATIO PLANNED/HOURLY RATIO
9 SRATIO SUPPORT/HOURLY RATIO
10 TRNG TRAINING HRS/CRAFTSPERSON
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6. Example Qwik Ratio Plot
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