jj616_chapter_4.0

JJ616:

MAINTENANCE MANAGEMENT

Instructor :

MOHD ZULFADLI BIN AHMAD

[email protected]

JJ616 MAINTENANCE MANAGEMENT

Upon completion of this chapter, students should be able to:-

Describe maintenance planning.

Understand maintenance scheduling.

Define maintenance inventory.

JJ616 MAINTENANCE MANAGEMENT

INTRODUCTION

Planning is the process by which the elements required to perform

a task are determined in advance of the job start.

Scheduling is the process by which jobs are matched with

resources and sequenced to be executed at a certain points in

time

Planning comes first then comes scheduling

It is possible that the unplanned or partially planned job will take

longer than expected or will rob resources from other jobs

resulting in the overall schedule being upset.

JJ616 MAINTENANCE MANAGEMENT MAINTENANCE PLANNING

Planning is the process of determining future decisions and

actions necessary to accomplish intended goals, and targets

Planning for future actions helps in achieving goals in the most

efficient and effective manner.

It minimizes costs and reduces risks and missing opportunities.

It can also increase the competitive edge of the organization

Concept & Steps


Maintenance planning procedures (steps)

Concept & Steps

Good planning is a prerequisite

for sound scheduling

Determine the job content

Develop work plan

Establish crew size for the job

Plan and order parts and material

Check if special tools &

equipment are needed

Assign workers with

appropriate skills

Review safety procedures

Set priorities for all maintenance

work

Assign cost accounts

Complete the work order

Review the backlog and

develop plans for controlling it

Predict the maintenance load

using effective technique


Concept & Steps

Planning process flow chart


Types of Planning

Typ

es o

f p

lan

nin

g

Long-range

planning

Medium-range

planning

Short-range

planning


Types of Planning

Long-range

planning

it covers a period of 3 to 5years and sets plans for future

activities and long range improvement.

sets plans for future activities and long-range improvement.


Types of Planning

it covers a period of 1 month to 1 year.

specify how the maintenance workers will operate.

provide details of major overhauls, construction jobs,

preventive maintenance plans, and plant shutdowns.

balances the need for staffing over the period covered.

estimates required spare parts and material acquisition.

Medium-range

planning


Types of Planning

it covers a period of 1 day to 1 week. It focuses on the

determination of all the elements required to perform

maintenance tasks in advance.

it focuses on the determination of all the elements required to

perform maintenance tasks in advance.

Short-range

planning


The maintenance job priority system has a tremendous impact

on maintenance scheduling.

Priorities are established to ensure that the most critical and

needed work is scheduled first.

The development of a priority system should be well

coordinated with operations staffs who commonly assign a

higher priority to maintenance work than warranted.

priority system should be dynamic and must be updated

periodically to reflect changes in operation or maintenance

strategies.

Related applications in industries & processes



Routine maintenance:

maintenance operations of a periodic nature

planned and scheduled and in advance

Emergency or breakdown maintenance:

Interrupt maintenance schedules in order to be performed

planned and scheduled as they happened

Design modifications

Planned and scheduled and they depend on eliminating the cause of repeated breakdowns.

Scheduled overhaul and shutdowns of the plant

Planned and scheduled in advanced

Overhaul, general repairs, and replacement

Planned and scheduled in advanced.

Preventive maintenance:

Planned and scheduled in advanced.



Priority of maintenance work

JJ616 MAINTENANCE MANAGEMENT MAINTENANCE SCHEDULING

A job priority ranking reflecting the criticality of the job.

The availability of all materials needed for the work order in the

plant.

The production master schedule.

Realistic estimates and what is likely to happen.

Flexibility in the schedule.

Requirements for scheduler


Requirements for scheduler

NO. TYPE OF

SCHEDULE

ACTIVITIES SOURCE OF INFORMATION

1 Long Term Lubrication

Inspection

Overhauling Cleaning of machine

Replacement of some items

Manufacturer Recommendation

Technical Experience

Analysis of life

analysis of history

2 Short Term Repairs

Replacement

Inspection reports

Complaints and requests of

operating personnel

the term long term means a plan for a period of a year or

more. Short term plan can be for a period between 15 days

to two months.


Long-

Range (master)

Schedule

Covering a period of 3 months to 1 year

Based on existing maintenance work orders

Balancing long-term demand for maintenance work with available resources

Spare parts and material could be identified and ordered in advance

Subject to revision and updating to reflect changes in the plans and maintenance work.

Weekly

Schedule

Covering 1 week.

Generated from the master schedule.

Allow 10% to 15% of the workforce to be available for emergency work

The schedule prepared for the current week and the following one in order to consider the available backlog.

The work orders scheduled in this week are sequenced based in priority

CPM and integer programming techniques can be used to generate a schedule

Daily Schedule

Covering 1 day.

Generated from weekly schedule.

Prepared the day before.

Interrupted to perform EM

Types and techniques based on functions & processes


The objective of the scheduling techniques is to construct a time chart

showing:

The start and finish for each job.

The interdependencies among jobs.

The critical jobs that require special attention and effective monitoring.

Such techniques are:

Modified Gantt chart

Critical Path Method (CPM)

Program Evaluation Review Techniques (PERT)

Integer and stochastic programming.

Scheduling Techniques


The Gantt Chart allows a manager to quickly determine what events

in a project are occurring at a specific point in time. The Gantt Chart

is good for managing projects having concurrent activities.

Scheduling Techniques


No above each box refers to the amount of a critical resource used

(usually time).

All events in the Critical Path Chart must be completed before the project

is considered complete

The Critical Path is the path that uses the most resources (like time).

If an event along the critical path consumes more than the scheduled

amount of resources, the whole delivery date of the project is delayed.

The Critical Path Chart helps a project manager focus attention and

resources on the path that consumes the largest amount of resources to

complete a project.

Scheduling Techniques Critical Path Method


Scheduling Techniques Program Evaluation Review

Techniques (PERT)


Scheduling Techniques Program Evaluation Review

Techniques (PERT)

a graphic illustration of a project as a network diagram consisting of

numbered nodes (either circles or rectangles) representing events, or

milestones in the project linked by labelled vectors (directional lines)

representing tasks in the project

direction of the arrows - sequence of tasks

for example, the tasks between nodes 1, 2, 4, 8, and 10 must be completed in

sequence. (dependent or serial tasks)

The tasks between nodes 1 and 2, and nodes 1 and 3 are not dependent on

the completion of one to start the other and can be undertaken

simultaneously. (parallel or concurrent tasks)

Tasks that must be completed in sequence but that don't require

resources or completion time are considered to have event dependency.

represented by dotted lines with arrows and are called dummy activities.

Ex: dashed arrow linking nodes 6 and 9 indicates that the system files must be

converted before the user test can take place, but that the resources and time

required to prepare for the user test are on another path


Scheduling Techniques Integer and Stochastic

Programming

Stochastic programming is a framework for modelling optimization

problems that involve uncertainty

problems are formulated with known parameters, real world problems

almost invariably include some unknown parameters

When the parameters are known only within certain bounds, one

approach to tackling such problems is called robust optimization.

Here the goal is to find a solution which is made for all such data and

optimal in some sense

Stochastic programming models are similar in style but take advantage of

the fact that probability distributions governing the data are known or can

be estimated

The goal here is to find some policy that is made for all (or almost all) the

possible data condition and maximizes the expectation of some function

of the decisions and the random variables

JJ616 MAINTENANCE MANAGEMENT MAINTENANCE INVENTORY

Concept and Advantages

The inventory is a list of physical features (area, material, etc.) of capital

assets that require maintenance.

maintenance functions rely heavily on the availability of items such as

spares for production equipment and machinery.

A well-managed inventory system of such items helps reduce

maintenance cost, worker and equipment downtime, and improves

productivity. Inventory control plays an important role in maintenance.


Concept and Advantages

ADVANTAGES OF MAINTENANCE

INVENTORY

Clear & frequent communication

among maintenance, inventory

management & purchasing

departments Active material planning by

maintenance, inventory

management, and purchasing

departments

Effective physical

control of parts

Enhanced item accuracy

Efficient material flow

from the storehouse to the customer

site

A customer service orientation by

inventory management and

purchasing departments


Types & techniques based on functions & processes

raw materials inventory,

items are purchased from suppliers for use in production processes

finished goods inventory

concerned with finished product items not yet delivered to customers

supplies inventory

concerned with parts/materials used to support the production process.

work-in-process (WIP) inventory

concerned with partly-finished items (i.e., components, parts, subassemblies, etc.) that have been started in the production process but must be processed further

transportation inventory

concerned with items being shipped from suppliers or to customers through the distribution channel

replacement parts inventory

concerned with maintaining items for the replacement of other items in the company or its customer equipment/systems as they wear out.


Maintenance management personnel respect to inventory

Items/materials to be stored

consideration of factors such as ability of the vendor to supply, cost, and the degree of deterioration in storage.

Amount of items/materials to be stored

Decisions are made by degree of usage and delivery lead time.

Item/material suppliers

Decisions are made by considering factors such as price, delivery, quality, and service

Lowest supply levels

Decisions in particular the major store items, are made by considering factors purchasings historical records and projected needs.

Highest supply levels

As time-to-time supply usage rate drops, the decisions are made by keeping in mind factors such as past ordering experience and peak vacation period.

Time to buy and pay

Decisions made by considering vendor announcements about special discounts, past purchasing records, and store withdrawals and equipment repair histories.

Place to keep items/materials

As location control is crucial to a productive. Maintenance department, decisions are made by keeping in mind that they can be effectively taken. Past experience indicates that a single physical location for each item is the best.

Appropriate price to pay

Pricing is of continuous concern, and decisions concerning it are primarily governed by perceived, not actual, supply and demand.

THE END Thank You

jj616_chapter_4.0

Documents

maintenance scheduling

maintenance workers

maintenance tasks

maintenance load

maintenance inventory

time planning

preventive maintenance

job plan