Maintenance Planning and Scheduling

TABLE OF CONTENTSSection1 Historical View of Maintenance 11.1 Pure Reactive1.2 Limited Proactive Applications1.3 Birth of Real Maintenance1.4 Military Takes the Lead in Maintenance1.5 Long Journey to Lean Thinking1.5.1 Lean Spills Over to Maintenance1.5.2 Maintenance Operation Refinements2 The Plant/Facility Lean Environment 2.1 Lean Origins and Definitions2.2 Lean Organization, Elements and Practices2.2.1 Current State2.2.2 Future State2.3 Lean Maintenance Operations2.3.1 Fundamentals of (Total Productive) Maintenance2.3.2 Lean Refinements2.3.3 Lean Maintenance: Prerequisite of the Lean Plant/Facility3 Governing Principles and Concepts of Lean Maintenance 3.1 Lean Maintenance Governing Principles and Concepts 3.1.1 Vision and Mission3.1.2 Strategic Plans, Goals and Targets3.2 Operations and Maintenance3.2.1 Operations-Maintenance - A Partnership with Two-Way Responsibilities3.2.2 A Lean Mandated Marriage3.3 Why Plan?3.3.1 Advantages of Maintenance Planning3.3.2 Objectives and Goals of Maintenance Planning4 Origins of the Maintenance Planner 4.1 In The Beginning4.2 Developing Standard Practices4.2.1 Basic Process4.2.2 Manufacturing’s Influence4.2.2.1 Accommodating a Varying Workload4.2.2.2 Resources, Resources, Resources4.2.3 Appearance of Balance5 Organization Alternatives5.1 Styles for Organizing Maintenance Operations5.1.1 Style Variations5.1.1.1 Incorporating Work Planning5.1.1.2 Planning and Scheduling: Defining the Role5.1.2 Total Productive Maintenance (TPM)5.1.3 Reliability Centered Maintenance (RCM)5.2 TPM-RCM-LEAN Organizational Considerations and Choices5.2.1 Where Does the Planner Fit?6 Performing the Planning Function6.1 Principles of Planning6.1.1 Managing the Backlog6.1.2 Criticality and Prioritization6.1.3 The Work Order6.1.3.1 Work Order Types and Formats6.1.3.2 Work Order System and Work Flow6.1.3.3 Coding Work Order Information6.1.4 Sequence of Planning6.1.4.1 Job Plan Level of Detail6.1.4.2 The Work/Job Package6.1.4.3 Estimating and Work Measurement6.1.4.4 Planning Aids6.1.5 The Role of CMMS in Maintenance Planning6.1.6 Feedback6.1.6.1 Building a History6.2 Closing out Work Orders6.2.1 Data Entry and Validation6.2.2 Maintenance/Reliability Engineering6.3 Lean Maintenance Planning7 Performing the Maintenance Scheduling Function7.1 Organizational Considerations7.2 Scheduling Defined7.2.1 Prerequisites for Effective Scheduling7.2.2 Preparing Schedules7.2.2.1 Scheduling Practices7.2.2.2 Scope of Maintenance Scheduling7.3 Metrics ¯ Schedule Compliance and Labor Effectiveness7.4 General Scheduling Considerations8 Special Case: Maintenance Planning and Scheduling for Maintenance Outages – The Plant Shutdown 8.1 Planned Outages Defined8.1.1 Phase I — Definition8.1.2 Phase II — Planning8.1.2.1 Purchasing – Plant Shutdown Logistics8.1.3 Phase III — Scheduling8.1.4 Phase IV — Execution8.1.5 Phase V — Debrief and Lessons Learned8.2 Critical Path Method Scheduling9 Tips, Tricks and Avoiding Pitfalls9.1 Straight from the Horse’s...9.2 Gaining Trust9.2.1 Attitudes, Practices and Methodologies for Success9.2.1.1 Skill Levels and Training9.2.2 Tips and Tricks of Successful Planners and Schedulers10 Metrics: Measuring Planning and Scheduling Performance 10.1 Planning and Scheduling Performance Indicators10.2 Maintenance Excellence and the P/S Function10.3 Summary: Characteristics of Maintenance