Measuring maintenance productivity has always been a challenge for asset-intensive industries. While organizations often track costs, downtime, and service completion, one key metric that shows how effectively technicians are spending their working hours is wrench time. This measure provides insights into how much of a technician’s day is spent on actual hands-on maintenance tasks versus time lost in delays, planning gaps, or administrative activities.
For maintenance managers, understanding wrench time is not just about efficiency numbers; it is about identifying obstacles that keep teams from working productively. When calculated and used correctly, wrench time helps in improving scheduling accuracy, resource allocation, and asset availability, leading to better overall reliability and reduced operating costs.
This article explains what wrench time means, why it matters, and how to calculate it effectively.
Understanding wrench time in maintenance management
Wrench time refers to the percentage of a maintenance technician’s working shift that is spent on actual physical maintenance work, such as repairing, replacing, or servicing equipment. It does not include indirect tasks like waiting for spare parts, walking to job sites, searching for tools, filling out paperwork, or attending meetings.
In simpler terms, wrench time separates “productive hands-on work” from “supporting or wasted time.” For example, if a technician works for 8 hours but only spends 3 hours actively repairing machines, the wrench time is 37.5%.
Why is calculating wrench time important in maintenance management?
Many industries assume technicians spend most of their time on tools, but studies often show actual wrench time averages between 25–35%. The rest is consumed in delays, miscommunication, or logistical inefficiencies. Tracking this metric reveals gaps that can be improved with better planning and coordination.
- Identifies productivity barriers: Low wrench time signals issues such as poor work order planning, unavailable spare parts, or excessive administrative load.
- Improves maintenance planning: When planners know how much hands-on time is available, they can schedule work more realistically.
- Reduces costs and downtime: Higher wrench time means more repairs are completed in less time, which directly impacts asset availability.
- Guides workforce management: Wrench time helps managers assess staffing requirements and training needs.
- Supports continuous improvement: Over time, it becomes a benchmark for evaluating improvements in maintenance processes.
How to calculate wrench time?
Calculating wrench time involves comparing the actual hands-on maintenance hours with the total paid or available work hours. The formula is straightforward:
Wrench Time (%) = (Direct Maintenance Hours ÷ Total Work Hours) × 100
Where:
- Direct Maintenance Hours = Time spent physically working on equipment (repairs, installations, replacements).
- Total Work Hours = Total shift hours (including waiting, travel, paperwork, breaks, etc.).
Example calculation:
- Technician shift = 8 hours
- Hands-on maintenance work = 3 hours
- Wrench time = (3 ÷ 8) × 100 = 37.5%
What are the impacts of high wrench time in the maintenance department?
A higher wrench time directly translates into better productivity, but its impact extends far beyond the number of hours worked. When maintenance teams spend more time on actual repairs, it positively affects cost control, equipment performance, and workforce morale.
- Increased equipment availability: More time spent repairing and servicing assets means fewer breakdowns and longer operational uptime.
- Lower maintenance backlog: High wrench time allows teams to complete more tasks in the same shift, reducing pending work orders.
- Reduced operational costs: Efficient use of technician hours means less overtime and fewer emergency breakdowns, which are typically costlier.
- Improved workforce utilization: Technicians feel more productive and valued when their time is used effectively, leading to higher job satisfaction.
- Better return on investment (ROI): Organizations see improved ROI on both human and asset resources when wrench time is consistently high.
Factors that reduce wrench time
Even skilled technicians can have low wrench time if processes are inefficient. Some common factors include:
- Waiting for spare parts or materials to arrive at the job site
- Searching for tools or safety equipment before starting work
- Delayed permits or approvals before beginning tasks
- Travelling long distances between job sites
- Excessive paperwork or reporting requirements
- Unclear instructions in work orders
How implementing a CMMS solution can help reduce wrench time?
A Computerized Maintenance Management System (CMMS) plays a key role in addressing the issues that lower wrench time. It provides a structured way to plan, execute, and monitor maintenance tasks, reducing delays and making technicians more productive on the floor.
- Centralized work orders: Technicians receive clear job instructions, asset details, and task lists through CMMS, eliminating confusion and wasted time.
- Real-time access via mobile apps: Field technicians can update job status, check equipment history, and access manuals instantly without needing to return to the office.
- Spare parts and inventory tracking: CMMS ensures required parts are available by linking work orders with inventory data, reducing downtime caused by missing spares.
- Smart scheduling and dispatching: Maintenance managers can assign tasks based on technician skills and proximity, cutting unnecessary travel and waiting time.
- Automated reporting and compliance: Instead of manually filling out forms, CMMS automates record-keeping, allowing technicians to spend more time on actual repairs.
Conclusion
Wrench time is a powerful metric for understanding how much of your maintenance team’s effort goes into actual productive work. A low wrench time does not mean technicians are underperforming—it highlights inefficiencies in planning, supply chain, or communication that must be resolved. By tracking and improving wrench time, organisations can ensure their maintenance resources are used effectively, leading to faster repairs, lower costs, and better equipment availability.
If you want to explore how digital maintenance tools like CMMS can help increase wrench time in your operations, reach out to us at contact@terotam.com
