JJ616:

MAINTENANCE MANAGEMENT

Instructor :
MOHD ZULFADLI BIN AHMAD
zulfadli@psmza.edu.my

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.

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

Concept & Steps

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

MAINTENANCE PLANNING

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Concept & Steps

Maintenance planning procedures (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

MAINTENANCE PLANNING

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Concept & Steps

Planning process flow chart

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

Types of planning

Types of Planning

Long-range
planning
Medium-range
planning
Short-range
planning

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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.

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

Types of Planning
Medium-range
planning
it covers a period of 1 month to 1 year.

specify how the maintenance workers will operate.

provide

details of major overhauls, construction

preventive maintenance plans, and plant shutdowns.

balances the need for staffing over the period covered.

estimates required spare parts and material acquisition.

jobs,

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

Types of Planning
Short-range
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.

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

Related applications in industries & processes

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.

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

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.

MAINTENANCE PLANNING

JJ616 MAINTENANCE MANAGEMENT

Related applications in industries & processes

Priority of maintenance work

MAINTENANCE SCHEDULING

JJ616 MAINTENANCE MANAGEMENT

Requirements for scheduler

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.

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JJ616 MAINTENANCE MANAGEMENT

Requirements for scheduler

NO. TYPE OF
SCHEDULE
1
Long Term

ACTIVITIES

SOURCE OF INFORMATION

Lubrication
Inspection

Manufacturer Recommendation
Technical Experience
Analysis of life
analysis of history

Overhauling
Cleaning of machine

Short Term

Replacement of some
items
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.

MAINTENANCE SCHEDULING

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Types and techniques based on functions & processes

LongRange
(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

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Scheduling Techniques
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.

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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.

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Scheduling Techniques Critical Path Method

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.

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JJ616 MAINTENANCE MANAGEMENT

Scheduling Techniques Program Evaluation Review

Techniques (PERT)

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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

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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

MAINTENANCE INVENTORY

JJ616 MAINTENANCE MANAGEMENT

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.

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JJ616 MAINTENANCE MANAGEMENT

Concept and Advantages

A customer service
orientation by
inventory
management and
purchasing
departments

Clear & frequent

communication
among maintenance,
inventory
management &
purchasing
departments

Active material
planning by
maintenance,
inventory
management, and
purchasing
departments

ADVANTAGES OF
MAINTENANCE
INVENTORY
Efficient
material flow
from the
storehouse to
the customer
site

Effective
physical
control of
parts
Enhanced
item accuracy

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JJ616 MAINTENANCE MANAGEMENT

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.

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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