MAINTENANCE STRATEGIES & APPLICATIONS

OBJECTIVES:

1. To understand what is planned &

unplanned maintenance

2. To understand why plan the maintenance

3. To know what happen if we not plan the

maintenance
 Form of Maintenance

MAINTENANCE

PLANNED MAINTENANCE UNPLANNED MAINTENANCE

PREVENTIVE PREDICTIVE PRE-PLANNED EMERGENCY

BREAKDOWN
TIMED-BASED CONDITION-BASED
RUN TO FAILURE
Maintenance Planning & Scheduling

One of the most effective ways to

control costs and improve
maintenance productivity

MAINTENANCE PLANNING AND

SCHEDULING
 Maintenance Planning & Scheduling

Definition:
MAINTENANCE PLANNING AND
SCHEDULING IS THE ALLOCATION OF
NEEDED RESOURCES AND MATERIALS
IN THE SEQUENCE IN WHICH THEY ARE
Maintenance Planning & Scheduling

NEEDED TO ALLOW AN ESSENTIAL

ACTIVITY TO BE PERFORMED IN THE
SHORTEST TIME AT THE LEAST COST
 Typical System Work Flow Diagram

WR

WORK CREATE WORK PREPN

SCHEDULING
IDENTIFICATN WORK ORDER & ESTIMATN

EMERGENCY

WORK CLOSE PERFORMCE

ANALYZE
PERFORMCE OUT REPORTING
 HOW IS MAINTENANCE PLANNING
DIFFERENT FROM SCHEDULING

MAINTENANCE PLANNING IS THE
ALLOCATION OF RESOURCES AND
MATERIALS
THE “WHAT” AND THE “HOW”

SCHEDULING IS THE ASSIGNMENT
OF MANY PREPARED(PLANNED)
JOBS
THE “WHEN”
 Maintenance Planning
& Scheduling

Provides the worker with an understanding of
the work and enough information to go directly
to the job site with the required materials and
tools

Perform the job with minimum delay and cost
with maximum efficiency

Reduces the non-productive time often
associated with maintenance work
 Not having the right parts
 Not having the right tools
 Not having the right skills, at the right place, at the
right time
 SYSTEM OF A BAD PLANNING AND
SCHEDULING

Poor job instruction resulting in delay,
confusion and lost time

Inadequate co-ordination of materials
resulting in false starts, delays, or makeshift
repairs

Poor co-ordination of crafts resulting in wait
time and idle personnel

Poor timing of equipment isolation and
shutdown resulting in excessive downtime
 Maintenance Planning consists of the
following:

Identification of work to be planned (job
scope)

Determination of work complexity and
composition

Estimation of manpower requirements

Identification of spare parts and other
materials – B.O.M. (availability)

Identification of special tools required

Use of standard job plan (if available)

Completed Permit-To-Work (P.T.W.)
 Maintenance Planning relies on…


Job Requests and Work Orders properly
completed

Work Order history

Planned Maintenance routine
 Preventive Maintenance
 Predictive Maintenance

Effective store and procurement process
 Effective material flow
 Why is Work Preparation and
Scheduling so important?

Unprepared work is:


3 to 4 times more expensive than
properly prepared work

Often requires more overtime

Typically more disruptive to the
production process
 Requirement for good scheduling…


Accurate estimates

Effective Work Order system including job
instructions, crafts required, required date

Accurate craft availability

Preventive and Predictive work that is due

Work Order backlog of “planned” and
“ready-to-go” work (at least 1 week per craft)
 Building the Schedule
W. O. # Task Description Skill Crew size Job Duration Manhours

1023998 Install limit switch on Finished product control MCC_01 E&I

1024001 Install conduit and pull wire E&I

1024002 Change motor on cooling fan HM2011 E&I

1024011 Reload program at raw product station PLC

1024003 Service Building X HVAC – quarterly Preventive Maintenance HVAC

1024004 Service Building Y HVAC – quarterly Preventive Maintenance HVAC

1024006 Change temperature transmitter at Boiler B301 Instrument

1024007 Boiler B301- quarterly calibration of instruments Instrument

1023999 Replace belt on conveyor drive MW

1024008 Install control valve at Tank T12 outlet MW

 Labour Productivity Losses

Waiting for instructions

Waiting for spare-parts

Looking for Supervisors

Checking out the work assignment

Multiple trips between the worksite and the
storeroom to obtain spare parts

Not having the proper tools

Waiting for approval to continue improperly
scoped work

Excessive Craft Technicians to the job.