maintenance planning and scheduling concepts

8/12/2019 Maintenance Planning and Scheduling Concepts

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1

Concepts of Maintenance Management

Lokesh Tayal, CMRP

Oracle Corporation Asia Pacific

[email protected]


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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


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Purpose of Maintenance

Risk Reduction

Least Operating Costs

Maintainer
http://www.mining-technology.com/projects/zaldivar/index.html


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4

Concepts of Maintenance Planning and

Scheduling


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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


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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.


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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


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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


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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!


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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


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Developing a Job Plan(Detailed in full in the Planning Procedure with process flow diagrams and descriptions)


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.


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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 world-

class content.


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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


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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


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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

maintenance planning and scheduling concepts

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