OBJECTIVES:

3. To know what happen if we not plan the maintenance

2. To understand why plan the maintenance

1. To understand what is planned & unplanned maintenance

MAINTENANCE STRATEGIES & APPLICATIONS

Form of Maintenance

MAINTENANCE

TIMED-BASED

PRE-PLANNED

PLANNED MAINTENANCE

PREVENTIVE

CONDITION-BASED

UNPLANNED MAINTENANCE

EMERGENCYBREAKDOWN

PREDICTIVE

RUN TO FAILURE

Maintenance Planning & Scheduling

One of the most effective ways to control costs and improve

maintenance productivity

MAINTENANCE PLANNING AND SCHEDULING

Maintenance Planning & Scheduling

Definition:

MAINTENANCE PLANNING AND SCHEDULING IS THE ALLOCATION

OF NEEDED RESOURCES AND MATERIALS IN THE SEQUENCE IN

WHICH THEY ARE NEEDED TO ALLOW AN ESSENTIAL ACTIVITY TO BE PERFORMED IN THE SHORTEST

TIME AT THE LEAST COST

Mai

nten

ance

Pla

nnin

g &

Sch

edul

ing

Typical System Work Flow Diagram

WR

WORK IDENTIFICATN

CREATE WORK ORDER

WORK PREPN & ESTIMATN

WORK PERFORMCE

CLOSEOUT

ANALYZE PERFORMCEREPORTING

SCHEDULING

EMERGENCY

MAINTENANCE PLANNING IS THE ALLOCATION OF RESOURCES AND MATERIALS

THE “WHAT” AND THE “HOW” SCHEDULING IS THE ASSIGNMENT

OF MANY PREPARED(PLANNED) JOBS

THE “WHEN”

HOW IS MAINTENANCE PLANNINGDIFFERENT FROM SCHEDULING

Maintenance Planning & Scheduling

Provides the worker with an understanding of the work and enough information to go directly to the job site with the required materials and tools

Perform the job with minimum delay and cost with maximum efficiency

Reduces the non-productive time often associated with maintenance work

Not having the right parts Not having the right tools Not having the right skills, at the right place, at the

right time

Poor job instruction resulting in delay, confusion and lost time

Inadequate co-ordination of materials resulting in false starts, delays, or makeshift repairs

Poor co-ordination of crafts resulting in wait time and idle personnel

Poor timing of equipment isolation and shutdown resulting in excessive downtime

SYSTEM OF A BAD PLANNING AND SCHEDULING

Maintenance Planning consists of the following:

Identification of work to be planned (job scope)

Determination of work complexity and composition

Estimation of manpower requirements Identification of spare parts and other

materials – B.O.M. (availability)

Identification of special tools required Use of standard job plan (if available)

Completed Permit-To-Work (P.T.W.)

Maintenance Planning relies on…

Job Requests and Work Orders properly completed

Work Order history Planned Maintenance routine

Preventive Maintenance Predictive Maintenance

Effective store and procurement process Effective material flow

Why is Work Preparation and Scheduling so important?

Unprepared work is: 3 to 4 times more expensive than

properly prepared work Often requires more overtime Typically more disruptive to the

production process

Requirement for good scheduling…

Accurate estimates Effective Work Order system including job

instructions, crafts required, required date Accurate craft availability Preventive and Predictive work that is due Work Order backlog of “planned” and

“ready-to-go” work (at least 1 week per craft)

Building the ScheduleW. O. # Task Description Skill Crew size Job Duration Manhours

1023998 Install limit switch on Finished product control MCC_01 E & I

1024001 Install conduit and pull wire E & I

1024002 Change motor on cooling fan HM2011 E & I

1024011 Reload program at raw product station PLC

1024003 Service Building X HVAC – quarterly Preventive Maintenance HVAC

1024004 Service Building Y HVAC – quarterly Preventive Maintenance HVAC

1024006 Change temperature transmitter at Boiler B301 Instrument

1024007 Boiler B301- quarterly calibration of instruments Instrument

1023999 Replace belt on conveyor drive MW

1024008 Install control valve at Tank T12 outlet MW

Waiting for instructions Waiting for spare-parts Looking for Supervisors Checking out the work assignment Multiple trips between the worksite and the

storeroom to obtain spare parts Not having the proper tools Waiting for approval to continue improperly

scoped work Excessive Craft Technicians to the job.

Labour Productivity Losses