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
TIMED-BASED

PREDICTIVE
CONDITION-BASED

PRE-PLANNED

EMERGENCY BREAKDOWN
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 NEEDED TO ALLOW AN ESSENTIAL ACTIVITY TO BE PERFORMED IN THE SHORTEST TIME AT THE LEAST COST

Maintenance Planning & Scheduling

Typical System Work Flow Diagram

WR WORK CREATE IDENTIFICATN WORK ORDER
EMERGENCY

WORK PREPN & ESTIMATN

SCHEDULING

WORK PERFORMCE

CLOSE OUT

ANALYZE

PERFORMCE REPORTING

HOW IS MAINTENANCE PLANNING DIFFERENT FROM SCHEDULING

q

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

q

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

q

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:

q

q q

q q q

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

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q q

Job Requests and Work Orders properly completed Work Order history Planned Maintenance routine

Preventive Maintenance Predictive Maintenance Effective material flow

Effective store and procurement process

Why is Work Preparation and Scheduling so important?

Unprepared work is: q 3 to 4 times more expensive than properly prepared work q Often requires more overtime q Typically more disruptive to the production process

Requirement for good scheduling

q q

q q q

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 E&I E&I E&I PLC HVAC HVAC Instrument Instrument MW MW Crew size Job Manhou Duration rs 1023998 Install limit switch on Finished product control MCC_01 1024001 Install conduit and pull wire 1024002 Change motor on cooling fan HM2011 1024011 Reload program at raw product station 1024003 Service Building X HVAC quarterly Preventive Maintenance 1024004 Service Building Y HVAC quarterly Preventive Maintenance 1024006 Change temperature transmitter at Boiler B301 1024007 Boiler B301- quarterly calibration of instruments 1023999 Replace belt on conveyor drive 1024008 Install control valve at Tank T12 outlet

Labour Productivity Losses

q q q q q

q q

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.