maintenance planning and scheduling concepts
TRANSCRIPT
-
8/12/2019 Maintenance Planning and Scheduling Concepts
1/15
1
Concepts of Maintenance Management
Lokesh Tayal, CMRP
Oracle Corporation Asia Pacific
-
8/12/2019 Maintenance Planning and Scheduling Concepts
2/15
Make Maintenance a Profit Centre
Save Money Make MoneyImprove the Maintenance
Systems and Equipment to
:
1) prevent equipment
failures,
2) reduce the need to domaintenance, and
3) optimise the use of
resources
Improve the Business
Systems and Equipment
to :
1) make more product,
2) make better quality
product, and3) make lower cost
product
-
8/12/2019 Maintenance Planning and Scheduling Concepts
3/15
Purpose of Maintenance
Risk Reduction
Least Operating Costs
Maintainer
http://www.mining-technology.com/projects/zaldivar/index.html -
8/12/2019 Maintenance Planning and Scheduling Concepts
4/15
4
Concepts of Maintenance Planning and
Scheduling
-
8/12/2019 Maintenance Planning and Scheduling Concepts
5/15
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
-
8/12/2019 Maintenance Planning and Scheduling Concepts
6/15
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.
-
8/12/2019 Maintenance Planning and Scheduling Concepts
7/15
Maintenance Planning is a
System to plan the right actions
Work Planning
System
Engineering FactsEngineering Standards
Equipment History Cost Estimates
Job Procedures
Time Estimates
Maintenance
Strategy Work Pack
PrecisionWorkmanship
Ideal Equipment
Conditions
Least
Distortion
In-Spec
Parts
Quality Work
Standards
Preparing Doing
Learning,
Observations,
Knowledge
-
8/12/2019 Maintenance Planning and Scheduling Concepts
8/15
www.lifetime-reliability.com
5 / 10 Year Maintenance Plan 1 Yr Plan 1 Mth Plan 1 Wk Plan Daily Plan
Long Term Plan
Short Term
Plan Locked-in Schedule
Strategic Tactical
Maintenance
Manager
Maintenance Maintenance
SupervisorPlanner
Maintenance Planners covert strategy into actions
that the crew uses to deliver the objective
-
8/12/2019 Maintenance Planning and Scheduling Concepts
9/15
Standardise the Work
Purpose of Standardised Work is to eliminate person-to-person variability and follow one best practice
way to do each job.
Have a precise description of each work activityspecifying 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, jobsin 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!
-
8/12/2019 Maintenance Planning and Scheduling Concepts
10/15
The Planning Workflow ProcessJob
Request
Checkout
Problem
Collect
Relevant
Details
Check
Equipment
History
Identify
Work
Needed;
Safety
Identify
Parts and
Resources
Cost
Work
Order
Materials
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
Develop
Job
Procedures
Update
KPIs; Do
Reporting
NOTE:It is a series work process with great
opportunity of causing added operating risk
-
8/12/2019 Maintenance Planning and Scheduling Concepts
11/15
Developing a Job Plan(Detailed in full in the Planning Procedure with process flow diagrams and descriptions)
www.lifetime-reliability.com
Task TimeminutesBest/Worst
By CostBest/Worst
Comments
Job: Replace Impeller on Process Chemical Pump R987
Materials in Store rack Bin 3C day prior 30/45 Storeman $1,500 Parts listed on WO M2435
Pick-up parts from Store Bin 3C 15/25 Tech $20/30 Check all parts against WO
Local Hazard Analysis (Process Plant Pump) 15/20 Tech $20/30 Take 5 in Work Pack
Bunting, floor protection, rubbish bin 15/20 Tech $20/30 Store provides in Bin 3C
Isolations (6 valves, 2 power supplies) 20/30 Operator $20/30 Procedure I26 in Work Pack,
Tags by Control Rm Super
Drain pump and piping 20/30 Op & Tech $32/50 Acid PPE
Handover 10/15 Op & Tech $12/20 Permit by Control Rm Super
Undo suction flange 15/20 Tech $20/30 Procedure F03 in Work Pack
Etc, Etc, Etc
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.
-
8/12/2019 Maintenance Planning and Scheduling Concepts
12/15
Job Procedures
This is where the
Maintenance Planner makes
the greatest difference for
their people.
www.lifetime-reliability.com
Help them do expert work
done faultlessly by giving
them world-class Job
Procedures with world-
class content.
-
8/12/2019 Maintenance Planning and Scheduling Concepts
13/15
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
-
8/12/2019 Maintenance Planning and Scheduling Concepts
14/15
How Much Maintenance Planning is Enough?
"In all things, success depends on previouspreparation, and without such preparation
there is sure to be failure." Confucius (Analects)
Big Planning
Job
Small
Small
Planning
Big Job
-
8/12/2019 Maintenance Planning and Scheduling Concepts
15/15
Work Schedulingis about
Time Management
Team / Relationship Building
Production Requirements and Limits
The Production Plan being the Maintenance Plan
Preparing Maintenance People to do the Job WellManpower and Resources Scheduling
Preparations before the Job Starts
Addressing Onsite Issues & Changes in the Plan
Monitoring Job Performance and Schedule
Backlog Management