Understanding Wrench Time in the Maintenance Industry

Introduction

Wrench time is the actual time technicians spend working on maintenance tasks—everything else, like waiting for parts or walking between jobs, doesn’t count. In manufacturing plants, where every minute matters, increasing wrench time is the key to boosting productivity. This post explains why wrench time is important, how to improve it, and what challenges you may face.

Why Wrench Time Matters

Wrench time measures how efficiently a maintenance team operates. Studies show that wrench time is often just 25-35% of a technician’s shift. The rest of the time is lost to paperwork, waiting for parts, or other delays. Improving wrench time means less downtime, lower labor costs, and better equipment performance. This translates into fewer production interruptions for plants, saving money and boosting output.

Key Components of Wrench Time

1. Work Planning
   Planning makes sure technicians have the tools, parts, and instructions they need before starting. It reduces delays and ensures they can work continuously, without distractions.
2. Tool and Part Availability
   Time is wasted when technicians have to search for or wait for tools or parts. Well-organized tool cribs and good inventory systems keep the essentials close at hand.
3. Clear Work Orders
   Clear instructions and safety procedures prevent confusion and rework. A good work order keeps technicians focused, helping them get the job done right the first time.

Best Practices for Wrench Time

1. Automate Administrative Tasks
   Use a CMMS to automate work orders, scheduling, and time logs. Reducing paperwork lets technicians spend more time working on maintenance.
2. Prepare Tools and Parts Ahead of Time
   Have everything ready before work starts. Pre-job briefings and kitting—gathering all necessary parts and tools beforehand—help technicians work without interruption.
3. Leverage Mobile Technology
   Equip technicians with mobile devices connected to your CMMS. They can access work orders and log time directly from the job site, without needing to return to the office.

Common Challenges and Solutions

1. Poor Planning
   Without proper planning, technicians waste time waiting for parts or instructions. Assign a dedicated planner to make sure work orders are complete and all materials are ready.
2. Miscommunication
   Miscommunication between maintenance and production teams slows down work. Real-time communication tools and regular check-ins help resolve issues faster.
3. Distractions from Non-Maintenance Tasks
   Technicians often get pulled into non-maintenance tasks, which eats into wrench time. Clearly define roles to ensure technicians stay focused on their core job—maintenance.

Conclusion

Improving wrench time is critical to the success of your maintenance operation. By planning work, keeping tools and parts readily available, and improving communication, you can significantly boost productivity. Apply these best practices to keep your maintenance team focused, reduce downtime, and keep your equipment running smoothly.