Course Details
Course Outline
10 days course
The Business Case for the Benefit of Planning (Why Do Planning?)
- Company Vision.
- Why Developing Is Needed in Maintenance?
- The concept of planning (e.g., Parts and Tools).
- Increase Your Workforce Without Hiring
- Case Study: The Practical Result of Planning.
- Is Freed-Up Technicians.
- “World Class” Wrench Time.
- The Specific Benefit of Planning Calculated for Labour Only.
- The Specific Benefit of Planning Calculated beyond Labour: The Ultimate Benefit.
- Plant Staffing Level.
- Why Does This Opportunity Exist?
- Quality and Productivity: Effectiveness and Efficiency.
- Planning Mission.
- Frustration with Planning.
Planning Principles (What Makes Planning So Frustrating and What Makes It Work?)
- The Planning Vision: The Mission.
- Principle 1: Separate Group.
- Principle 2: Focus on Future Work.
- Principle 3: Component Level Files Illustrations.
- Principle 4: Estimates Based on Planner Expertise.
- Principle 5: Recognize the Skill of the Crafts.
- Principle 6: Measure Performance with Work Sampling.
Scheduling Principles (Why Do We Have to Do Scheduling and What Makes It Work?)
- Why Maintenance Does Not Assign Enough Work?
- Advance Scheduling Is an Allocation.
- Principle 1: Plan for Lowest Required Skill Level Illustrations.
- Principle 2: Schedules and Job Priorities Are Important Illustrations.
- Case Study: New Supervisor.
- Case Study: Honouring the Schedule.
- Principle 3: Schedule from Forecast of Highest Skills Available.
- Principle 4: Schedule for Every Work Hour Available.
- Principle 5: Crew Leader Handles Current Day’s Work.
- Principle 6: Measure Performance with Schedule Compliance.
Success Only After Dealing with Reactive Maintenance
- Proactive versus Reactive Maintenance.
- Extensive versus Minimum Maintenance.
- What Kind of Job Plan Is That!?
- Case Studies Illustrating Actual Industry Successes.
- Case Study: Electric Utility.
- Case Study: Chemical Plant.
- Case Study: Food Processing.
- Case Study: Facilities 1.
- Case Study: Facilities 2.
- Case Study: Paper Mill.
- Case Study: Wastewater Treatment Plant.
Basic Planning
- A Day in the Life of a Maintenance Planner Work Order System.
- Planning Process.
- Work Order Form.
- Coding Work Orders.
- Using and Making a Component Level File Scoping a Job.
- Troubleshooting.
- Performance Testing or Engineering.
- Engineering Assistance or Reassignment.
- Developing Planned Level of Detail, Sketching and Drawing.
- Job Plan Template.
- Estimating Work Hours and Job Duration.
- Job Safety.
- Estimating Job Cost.
- Contracting Out Work.
- Wastewater Treatment Industry Example.
Advance Scheduling
- Weekly Scheduling.
- Forecasting Work Hours.
- Sorting Work Orders.
- Allocating Work Orders.
- Common Sense for Interruptible and Other Work.
- Formal Weekly Schedule Meeting.
- Staging Parts and Tools.
- What to Stage?
- Where to Stage?
- Who Should Stage?
- The Process of Staging.
Daily Scheduling and Supervision
- A Day in the Life of a Maintenance Supervisor.
- Assigning Names 273 Coordinating with the Operations Group.
- Handing Out Work Orders.
- During Each Day.
- Avoiding Common Pitfalls That Wreck the Schedule.
Forms and Resources Overview
- Forms.
- Resources.
- Component Level Files—Mini files.
- Equipment History Files (Including System Files and Mini files)
- Technical Files.
- Attachment Files 308 Vendor Files.
- Equipment Parts Lists.
- Standard Plans.
- Lube Oil Manual.
- MSDS.
- Plant Schematics.
- Rotating or Critical Spares Programme.
- Security of Files.
The Computer in Maintenance
- A Day in the Life of a Maintenance Planner (Using a CMMS).
- The Planner Must Use the CMMS Job Plan Module.
- What Type of Computerization.
- Software Already in Use.
- Single User or Larger Network.
- Creating versus Purchasing a Commercial CMMS.
- Interfacing a CMMS with a Company Financial System.
- Benefits with the CMMS.
- Standardizing Work Processes Inventory Control.
- Information for Metrics and Reports.
- Finding Work Orders.
- Linking Information to Equipment.
- Common Database Scheduling.
- PM Generation.
- Problem Diagnosis and Root Cause Analysis Support.
- Cautions with the CMMS.
- Selection of a CMMS.
How Planning Interacts with Preventive Maintenance, Predictive Maintenance, and Project Work
- Preventive Maintenance and Planning.
- Project Work and Planning.
Control (How Do We Control Planning Itself and What Are Associated KPIs for Planning and Overall Maintenance?)
- Key Process Indicators (KPIs).
- KPIs for Scheduling.
- KPIs for Planning.
Shutdown, Turnaround, Overhaul, and Outage Management
- Different Types of Outages.
- Accuracy of Task Estimates.
- Cycle of Improvement: The Outage Report.
- Controlling the Scope of Outages.
- Elements of the Outage Organization.
- Defining Outage Success.
Start Planning
- What Is Maintenance Planning?
- Why Do Companies Need Maintenance Planning?
- WIIFM (What’s in It for Me?)
Planning Is Just One Tool; What Are the Other Tools Needed?
- Work Order System.
- Leadership, Management, Communication, Teamwork.
- Qualified Personnel.
- Reliability Maintenance.
- Improved Work Processes.
What to Buy and Where
- Mini file Folders.
- Mini file Labels.
- Miscellaneous Office Supplies.
- Equipment Tags.
- Recommended Tag Sizes and Colours.
- Wire to Hang Tags on Equipment Deficiency Tags.
- Shop Ticket Holders.
- Open Shelf Files.
- CMMS.
Overview of Duties for Planners and Others
- Maintenance Planner.
- Maintenance Scheduler.
- Maintenance Planning Clerk.
- Operations Coordinator or Gatekeeper.
- Maintenance Purchaser or Expediter.
- Crew Supervisor.
- Planning Supervisor.
- Maintenance Manager.
- Maintenance Planning.
- Project Manager.
- Maintenance Analyst.
Computerized Maintenance Management Systems and Scheduling with Excel Spreadsheets
- Planning Principles versus Using a CMMS.
- Helpful Features for Planning and Scheduling.
- Types of Projects.
- Planning for a CMMS.
- Ongoing Support.
- Scheduling with Computer Spreadsheets.
- The MPSH Scheduler Excel Spreadsheet.
Establishing and Supporting a Planning Group
- Setting Up a Planning Group in a Traditional.
- Redirecting or Fine-Tuning an Existing Planning Group.
- Aids and Barriers Overview.
- Major Areas of Planning Management.
- Key Aids and Barriers.
- – Examples.
Contracting Out Work
- Why Contract Out Work?
- Problems with Contracting Out Work.
- Alternative Forms of Contracting Out Work.
- Arbitration Considerations for Contracting Out Work.
- Concise Text of Missions, Principles, and Guideline.
