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Maintenance Planning and Scheduling Concepts

This document discusses key concepts in maintenance management, planning, and scheduling. It outlines how to improve maintenance systems to prevent failures, reduce needed maintenance, and optimize resource use. It also describes the roles of maintenance planning and scheduling in developing work plans, coordinating with production, and minimizing disruptions. Standardizing work and developing detailed job plans and procedures are emphasized as important parts of the planning process.

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Tran Tai
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2K views15 pages

Maintenance Planning and Scheduling Concepts

This document discusses key concepts in maintenance management, planning, and scheduling. It outlines how to improve maintenance systems to prevent failures, reduce needed maintenance, and optimize resource use. It also describes the roles of maintenance planning and scheduling in developing work plans, coordinating with production, and minimizing disruptions. Standardizing work and developing detailed job plans and procedures are emphasized as important parts of the planning process.

Uploaded by

Tran Tai
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Concepts of Maintenance Management

Lokesh Tayal, CMRP Oracle Corporation Asia Pacific Lokesh.tayal@oracle.com


1

Make Maintenance a Profit Centre


Save Money
Improve the Maintenance Systems and Equipment to : 1) prevent equipment failures, 2) reduce the need to do maintenance, and 3) optimise the use of resources

Make Money
Improve the Business Systems and Equipment to : 1) make more product, 2) make better quality product, and 3) make lower cost product

Purpose of Maintenance

Least Operating Costs

Maintainer Risk Reduction

Concepts of Maintenance Planning and Scheduling

Role of Maintenance Planning


Develop and collate detailed work plans, including information, procedures and standards. Assemble the correct components and parts. Permit repairs and maintenance to be done correctly, accurately, safely, quickly, and without interruption during execution. Cause the least production disruption.
Planners turn the maze into a map

Role of Maintenance Scheduling


Coordinate with Production for the time and methods to access plant and equipment.

Ensure repairs and maintenance can be done safely and correctly.


Cause the least production disruption.

Maintenance Planning is a System to plan the right actions


Time Estimates
Engineering Standards Engineering Facts In-Spec Parts

Ideal Equipment Conditions

Maintenance Strategy

Work Planning System

Preparing Doing

Work Pack

Least Distortion

Equipment History

Cost Estimates Job Procedures


Quality Work Standards

Precision Workmanship

Learning, Observations, Knowledge

Maintenance Planners covert strategy into actions that the crew uses to deliver the objective
Maintenance Maintenance Maintenance

Manager
5 / 10 Year Maintenance Plan

Planner
1 Yr Plan 1 Mth Plan

Supervisor
1 Wk Plan Daily Plan

Long Term Plan Strategic

Short Term Plan


Tactical

Locked-in Schedule

www.lifetime-reliability.com

Standardise the Work


Purpose of Standardised Work is to eliminate personto-person variability and follow one best practice way to do each job.

Have a precise description of each work activity specifying task accuracy, cycle time, the work sequence of specific tasks, the parts on-hand and tools needed to conduct the activity expertly.
Find the best-practice method of doing work (individual job, jobs in a team, jobs in a process) Have everyone doing the jobs do them in the same standard way (take the variability out of the person-to-person aspect of each job) Ask people to continuously improve how these jobs are done (seek higher quality and productivity)

This is the only way we do it here!

The Planning Workflow Process


Job Request

NOTE: It is a series work process with great opportunity of causing added operating risk
Identify Work Needed; Safety

Checkout Problem

Collect Relevant Details

Check Equipment History

Identify Parts and Resources

Cost Work

Order Materials

Develop Job Procedures

Build Work Pack

Collect Materials Together

Schedule the Job with Production

Issue the Job

Collect Job History

Update Data Bases

Update Planning Procedures

Update Job Procedures

Update KPIs; Do Reporting

Developing a Job Plan


(Detailed in full in the Planning Procedure with process flow diagrams and descriptions) To control a maintenance job, you need to remove the risk of things going wrong and encourage those outcomes that need to be done right. This needs a detailed job plan.
Task Time
minutes
Best/Worst

By

Cost
Best/Worst

Comments

Job: Replace Impeller on Process Chemical Pump R987 Materials in Store rack Bin 3C day prior Pick-up parts from Store Bin 3C Local Hazard Analysis (Process Plant Pump) Bunting, floor protection, rubbish bin Isolations (6 valves, 2 power supplies) Drain pump and piping Handover Undo suction flange Etc, Etc, Etc 30/45 15/25 15/20 15/20 20/30 20/30 10/15 15/20 Storeman Tech Tech Tech Operator Op & Tech Op & Tech Tech $1,500 $20/30 $20/30 $20/30 $20/30 $32/50 $12/20 $20/30 Parts listed on WO M2435 Check all parts against WO Take 5 in Work Pack Store provides in Bin 3C Procedure I26 in Work Pack, Tags by Control Rm Super Acid PPE Permit by Control Rm Super Procedure F03 in Work Pack
www.lifetime-reliability.com

Job Procedures
This is where the Maintenance Planner makes the greatest difference for their people. Help them do expert work done faultlessly by giving them world-class Job Procedures with worldclass content.
www.lifetime-reliability.com

Equipment Performance Trending


Bad Actors Monitoring Mean Time Between Failure (MTBF) Mean Time to Repair (MTTR) Repeat Failures Uptime / Downtime Improvement/Change over a Time Period

How Much Maintenance Planning is Enough?


"In all things, success depends on previous preparation, and without such preparation there is sure to be failure." Confucius (Analects)

Big Job Job Small Small Planning Big Planning

Work Scheduling is about


Time Management Team / Relationship Building Production Requirements and Limits The Production Plan being the Maintenance Plan Preparing Maintenance People to do the Job Well Manpower and Resources Scheduling Preparations before the Job Starts Addressing Onsite Issues & Changes in the Plan Monitoring Job Performance and Schedule Backlog Management

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