Class 11 - Maintenance Planning

7/30/2019 Class 11 - Maintenance Planning

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Introduction

Effective planning and scheduling contribute significantly tothe following:

Reduced maintenance cost.

Improved utilization of the maintenance workforce byreducing delays and interruptions.

Improved quality of maintenance work by adoptingthe best methods and procedures and assigning themost qualified workers for the job.

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Industrial Engineering


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Introduction

Planning and Scheduling Objectives

Minimizing the idle time of maintenance workers.

Maximizing the efficient use of work time, material,

and equipment.

Maintaining the operating equipment at a responsivelevel to the need of production in terms of deliveryschedule and quality.

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Introduction

Maintenance work can be classified according toplanning and scheduling purposes

Routine maintenance: are maintenance operationsof a periodic nature. They are planned andscheduled and in advance. They are covered by

blanket orders.

Emergency or breakdown maintenance: interruptmaintenance schedules in order to be performed.They are planned and scheduled as they happened

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Introduction

Design modifications: are planned and scheduledand they depend on eliminating the cause ofrepeated 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 inadvanced.

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Maintenance Planning

Planning is the process of determining futuredecisions and actions necessary to accomplish

intended goals, and targets. Planning for futureactions helps in achieving goals in the most efficientand effective manner. It minimizes costs and reducesrisks and missing opportunities.

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Planning comprises all the functions related to thepreparation of:

1. The work order

2. Bill of material

3. Purchase requisition

4. Necessary drawings

5. Labor planning sheet including standard times

6. All data needed prior to scheduling and releasingthe work order.

Good planning is a prerequisite for sound scheduling.

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Planning Procedures

1. Determine the job content.2. Develop work plan. This entails the sequence of

the activities in the job and establishing the bestmethods and procedures to accomplish the job.

3. Establish crew size for the job.

4. Plan and order parts and material.

5. Check if special tools and equipment are neededand obtain them.

6. Assign workers with appropriate skills.

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Planning Procedures

8. Review safety procedures.9. Set priorities for all maintenance work.

10. Assign cost accounts.

11. Complete the work order.

12. Review the backlog and develop plans forcontrolling it.

13. Predict the maintenance load using effectiveforecasting technique.

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Planning Techniques

Basic Levels of Planning Process (Depend onThe Planning Horizon

Long-rang planning: it covers a period of 3 to 5years and sets plans for future activities and long-range improvement.

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

Short-rang planning: it covers a period of 1 day to 1week. It focuses on the determination of all theelements required to perform maintenance tasks in

advance.

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Planning Techniques

Long and Medium-Range Planning

Needs to utilize the following: Sound forecasting techniques to estimate the

maintenance load.

Reliable job standards times to estimate staffingrequirements.

Aggregate planning tools such as linearprogramming to determine resource requirements

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Planning Techniques

Medium-Range Planning

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 periodcovered.

Estimates required spare parts and materialacquisition

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Planning Techniques

Short-Range Planning

It focuses on the determination of all the elementsrequired to perform maintenance tasks in advance

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Documents

Class 11 - Maintenance Planning