5 Day Maintenance Planning & Scheduling

Effective & Reliable Maintenance is no longer optional to be competitive in the fast pace global business world. Effective planning and scheduling contribute significantly to the following:

• Reduced maintenance cost. Avoiding over insurance on outdated equipment/assets.
• Improved utilization of the maintenance workforce by reducing defects; delays and downtimes.
• Waste elimination and cost reductions due to “uptime” (first time right).
• Improved people and motivation leading to internal & external customer satisfaction.
• Improved management & leadership; resulting in greater team effectiveness.
• Improved quality of maintenance work regarding man; machine; methods & materials.
• Inventory reduction and production improvement in TAKT time; Cycle time; and Standard time.

 

This uniquely developed course focuses on waste elimination; equipment reliability; FMEA; Planning; Scheduling and Shutdown Management. Our comprehensive soft copy templates is Excel; Six Sigma & Kaizen based and introduces you to best practice maintenance planning and scheduling systems. Delegates bring their laptops; upload over 30 templates, work on them in groups; and leave the training empowered to go and implement in their workplace. This computerized course requires Windows 2003 – 8 and only basic knowledge of Excel; WORD and Power Point. All templates are simplified and easy to use as an added advantage to delegates.

This course is designed for a wide audience:

• Maintenance Artisans: Ready for promotion
• Maintenance Supervisors: Realize their critical role at implementation level and cooperation with others
• Maintenance Managers: Interfacing with all other departments for scarce resources. Support from a team point of view in production; logistics and plant facilities
• Logistics Supervisors & Mangers: In order to recognize the importance of critical spares; tools and equipment and agree on a level of safety stock and critical spares
• Plant Managers: They are frustrated with machine downtime and poor motivation; maintenance – the solution
• Plant Engineers: They are in the position to design out repetitive errors by innovation and creativity.
• Maintenance Planners: They need to realize the importance of effective communication and be aware of who; what; when; how; why regarding shut downs and preventative Maintenance. The author developed 12 maintenance types.
• Management Information staff: Understand the role of CMMS in maintenance; difficult to balance
• Project managers: Modern maintenance is done as projects. Specific shutdowns and line upgrades.
• Risk Management Professionals: The importance of care of physical assets and incident and accident preventions by evaluating equipment unsafe acts and unsafe conditions. Complete risks FMEA templates.
• Financial Managers: They must plan the future budgets and strategies going forward and need to know what we have and what not. Is the MRP system accurate? Why not?

The objectives of this course include an understanding of:

1. Maintenance Planning: It’s Role in the Business and its Foundation Basics. Maintenance history; present and future
2. The 12 types of maintenance as developed by the facilitator
3. The Purpose and Role of Maintenance Planning and Scheduling; including practical’s
4. Risk Management Fundamentals
5. Equipment Criticality Analysis – identify plant and equipment at risk and a discussion on the use of technology as a tool for Optimization of Operations and Maintenance activities
6. Classification of Maintenance Work According to Planning and Scheduling Purposes
7. Planning and Maintenance Key Performance Indicators (KPI)
8. Maintenance Effectiveness Indicators (MTBF; FR; MTTR etc.)
9. The Maintenance Planning Work Process
10. Necessary Planning Office Systems and Methods
11. Standardizing Planning and Scheduling Procedures
12. Equipment Refurbishment Decisions and Costs
13. Elements of Sound Scheduling
14. Staging Parts and Tools; What, Where and Who to stage, the process of staging; group work and exchanging ideas
15. Work Scheduling & Job Sequencing group discussions
16. Manpower Scheduling and Resources Scheduling
17. Measurement of Maintenance effectiveness with Metrics
18. The People Side of Planning; 12 Motivation tips.
19. Specific Planning Advice to go along with a CMMS database
20. Effective Shutdown Execution; examples out of industry

The Overall Objectives of this course includes:

• Minimizing the idle time (tool time) of maintenance workers.
• Maximizing the efficient use of work time, material, and equipment; out with the old and in with the new
• Maintaining the operating equipment at a responsive level to the need of production in terms of delivery schedule and quality. Aid production to achieve TAKT and Cycle times
• Determine the correct load on machines and equipment – eliminate overload or under load. This leads to a correct make or buy decision on the strategic management level
• Use maintenance as an effective method of cost reduction and improving uptime. Maintenance saves money
• Make the entire facility more efficient in all areas.

Practical exercises of the different tools to help delegates find the methods that are the easiest for them or those that work best under certain conditions (Project Management Tools)

1. The ratio of theory to practical is: 20% theory; 80% practical; including working on soft copies
2. Case Studies will be provided and worked through with delegates in a separate workbook supplied        

DAY 1: INTRODUCTION TO MAINTENANCE PLANNING & RISK MANAGEMENT

Maintenance Planning:

It’s Role in the Business and its Foundation Basics      

• Fundamental Laws of Manufacturing & Maintenance – group discussion
• What Planning mainly is and what it is not
• Improvement by Banishing Waste. The author has developed solutions to the 12 most critical wastes using a combination of the Toyota Production System; Six Sigma and Lean.
• Quality and Productivity; Effectiveness and Efficiency; the author has developed easy to use statistical process control tools (soft copy)
• Proactive versus Reactive Maintenance
• Communication and Management Support
• Desired Level of Effectiveness including the OEE; MTTR; MTBF; FR calculations
• Benefits of Work Planning & Scheduling - accuracy; cost saving; materials; time saving
• Work Planning & Scheduling in Context  
• The Role of Work Planning and Control   
• Planning Principles – all three levels are described with roles and responsibilities
• Planning Department – what they should have and not have; their unique challenges  
• Estimates Based on Planner Expertise – involving finance in strategic decisions

    

Maintenance Objectives and Methodologies

•    The purpose and objectives of Maintenance explained in relation to the entire business

•    The Purpose and Role of Maintenance Planning and Scheduling; considering factors such as capacity; utilization & Overall Equipment Effectiveness.    

Strategic Importance of Planning Maintenance

•    The Asset Management ‘Journey’

•    Choosing a Maintenance Methodology    

•    Plant and Equipment Life Cycle, Life Cycle Costs / Life Cycle Profits / Value depreciation       

•    Equipment Conditions Monitoring (trend analysis)

•    Consideration of Preventive Maintenance, Predictive Maintenance, and Project Work

•    Condition-based Maintenance – 5 Senses.          

Risk Management Fundamentals  

• Match Maintenance Strategies to Risk Analysis in order of severity       
• Criticality and Probability of Occurrence tools like historical data and others are practiced.
• Equipment Criticality Analysis – identify plant and equipment at risk using the Critical Path Method (CPM) out of the Project Management disciplines and easy to use templates are provided.
• Ten Steps to Failure Management (‘Due Processes’).    
• Using Condition Monitoring to Test Work Quality/Measure Machine Baseline Condition
• Defect and Failure True Costs and Evaluate the Risk Associated with Failure Events
• 6 types of costs are explained and practiced out of the TQM philosophy.
• Failure Mode and Effects Analysis (FMEA) – identify parts at risk and necessary maintenance; including risks caused by inventory; production; engineering any specific types – Excel template.
• Failure Prevention and Defect Elimination Maintenance Procedures     

 What is Reliability-centred Maintenance RCM?

• RCM as a tool for Optimization of Operations and Maintenance activities         
• International Engineering and Equipment Care Standards
  • Alignment and Distortion   
  • Lubrication methods and chemicals  
  • Balance and Vibration analysis (CBM)

 

DAY 1 (Continued)

 

• Bearing/Shaft Clearances 
• Looseness 
• Contamination and Cleanliness    
• Proactive Inspection and Detection Rounds/Watch keeping       
• Classification of Maintenance Work According to Planning and Scheduling Purposes
• Precision Maintenance for Maximum Failure Free Lifespan – Weibull curve optimization

 

Planning and Maintenance Key Performance Indicators

•    Planning and Maintenance Key Performance Indicators (KPI)   

•    Maintenance Performance Prediction Indicators (MTBF group calculation)

•    Maintenance Effectiveness Indicators (various)

•    Equipment Performance Indicators (Specifications; tolerances; clearances)

•    Production Performance Indicators (TAKT; Cycle; Capacity; Flow; Load).         

•    Planning Indicators – who; when; what; how why with 8D and IS-IS NOT Excel template

•    Job Quality Indicators – What is QC; QA and QM really? How does it work? Toyota Way

Practical’s and group discussions

 

The Maintenance Planning process          

•    Work Order Elements to be coded           

•    Scoping-out a Job

•    Closing & Filing – why is the information so incomplete? Why do artisans not record?

•    Feedback that should be received; why is it neglected?  

 

Necessary Planning Office Systems and Methods         

•    Work Order Costing          

•    Plant and Equipment Information 

•    Planning Documents and Equipment Records and their Control

•    Job Procedures – organising and reorganising.

•    Job Records and their Control      

•    Equipment Performance Trending

 

Specifying Workmanship Standards        

•    Standardised Work – is it according to true time standards?        Are you running to failure?

•    Setting the Standards for a Job – time; ergonomics; ILO allowances.    

•    Failure Preventing Job Procedures.         

 

Inventory Purchasing and Management   

•    Equipment Refurbishment Decisions and Costs

•    Important Purchasing Information – economic order quantity (EOQ).    

 

DAY 2: SPARES & WORK PLANNING

 

Critical spares and components

• Useful Store Control and Storage Practices – the 7 negatives of keeping inventory.     

•    Good Storage Practices – FIFO; LIFO;

•    Working with and Developing Suppliers – modern supply chain introduction.

The Work Planning Process           

•    Work Order System

•    Scoping a Job

•    Performance testing or engineering

•    Prepare the resources      

•    Plan how to Collect Information from the Job

•    Engineering Assistance or Reassignment

•    Work Order Form

•    Coding Work Orders

•    Estimating Work Hours and Job Duration

•    Equipment parts list

•    Purchasing, Storeroom, reserving, and staging

•    Special Tools

•    Job Safety and Material safety data sheets

•    Estimating Job Cost

•    Closing and Filing Feedback after Job Execution

 

DAY 3: SCHEDULING

 

Principles of Scheduling    

•    Skills required for Scheduling       

•    Job Records and their Control      

•    Equipment Performance Trending

•    Job Performance Trending           

•    Site Investigation   

•    Root Cause Analysis

•    Failure History

•    The critical path (CPM)

•    Bar Charts & Gantt Charts

•    Resource smoothing         

•    Managing the Critical Path

 

Advance Scheduling

• Weekly Scheduling

Forecasting work hours

Sorting work orders

 Allocating work orders

• Formal Weekly Schedule Meeting
• Staging Parts and Tools; What, Where and
• Who to stage, the process of staging
• Key concepts in scheduling for outages & Planning work orders for outages
• Quotas, Benchmarks, and Standards Addressed

 

Work Scheduling     

• The Scheduling Meeting   
• Work Request for a Planned coverage

 

DAY 4: PROACTIVE MAINTENANCE

 

• Proactive versus reactive maintenance
• Reactive work hours
• Schedule forecast
• Schedule compliance
• Wrench time
• Cost Management in Maintenance Planning
  • Identifying and controlling maintenance costs
  • Budgeting for maintenance activities
  • Cost-Benefit Analysis: Evaluating the cost vs. benefits of maintenance strategies
  • Maintenance cost categories: Direct, indirect, fixed, and variable costs
  • Strategies to reduce maintenance costs (preventive measures, predictive analysis)
  • Financial impact of downtime and delays on operations
  • ROI on Maintenance Investments: Analyzing return on investment for maintenance projects

 

Use of KPIs to track cost efficiency in maintenance

• The Required Documentation
• Plan for Lowest Required Skill Level & Forecast of Highest Skills Available
• Schedule for Every Work Hour Available

 

 

 

DAY 5: CONTROL & SHUTDOWN MANAGEMENT

 

Scheduling Control

•    Job Planning and Review Meetings         

•    Preparations before the Job Starts           

•    Complete the Checklists   

•    Job and Workmanships Feedback, Post-Job Review, and Lessons Learnt Meeting

•    Continuously Improving the Planning       

 

Relationship building          

•    The People Side of Planning - Motivation

•    Identify planning/scheduling value add    

•    Bring groups together to cooperate          

•    Request others improvement ideas          

•    The Production Plan         

•    Liaison with Production     

•    Scheduling into the Production Plan        

 

CMMS

•    Selection of a CMMS

•    Planning a CMMS Project

 

Shutdown Management

•    Overview of Shutdown Management       

•    Conditions for Successful Shutdowns      

•    Shutdown work identification        

•    Shutdown work scope       

•    Pre-shutdown work           

•    Sources of shutdown work

•    General shutdown checklist         

•    Compiling identified work 

•    Parts, material and equipment      

•    Constraints of shutdowns  

•    Preliminary costs estimate to budget        

•    Work Packages     

•    Roles of operation 

 

 

Discussions, Practical Exercises and Case Study

Excel and Project Management templates

 

Other Maintenance Improvement Courses that we offer include:

Practical Root Cause Analysis

Reliability Centered Maintenance (RCM)

Developing Multi Skilled Supervisors

Implementing a Cost Saving Project 

Implementing a Six Sigma Excel Project

Failure Mode & Effect Analysis (FMEA)

Pneumatics & Hydraulics maintenance

Compressor & Slurry Pump Maintenance