BEST PRACTICES IN JOB PLAN CREATION Northern California Maximo User Group Santa Rosa, CA October 6, 2016 Matt Midas
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
BESTPRACTICESINJOBPLANCREATION
NorthernCaliforniaMaximoUserGroupSantaRosa,CAOctober6,2016MattMidas
2
Agenda• Introductions• EAMvsWorldClassMaintenance
• BigData?
• JobPlans
• Whattodo
• TheimpactofJobPlans• Conclusion
• QuestionsandAnswers
3
Introduction• USCoastGuardLicensedEngineer–unlimitedhorsepower,steam
anddieselpropulsionplants
• Sailed2yearsonmerchantships(85–86)
• Served3yearsintheNavyasanengineeringofficer–SWO,EOOW,DCA,RPL,CICWO,OODqualified(87–90)
• CharlestonNavalShipyard–repairandoverhaulofS5W/S6Gnuclearreactorplants(90–93)
• PlantoperationsandMaintenanceManagerfor186buildingsinWashingtonDC(93–97)
• PSDI/MROSoftware–solutionsarchitectforMaximo(97–05)
• GenesisSolutions/ABS-MaximoimplementationsandReliabilityimprovements(05–16)
• Solufy–deliveringefficientandsimpletouseplanningandschedulingsolutionsforMaximo(16–__)
4 4
WorkOrders
PlanningvScheduler
vJobPlan
SchedulingvScheduler
AssigningvScheduler
AvailabilityvCalendar
• SeeyourworkordersfromMaximoinoneGantt• Loadthousandsofworkorderseasily• Noneedformultipleschedules• Noimpacttoperformance• Workordersthatmeetyourrequirements• ViewMetricsandComplianceReporting
• Add/Updatecraftrequirements
• Add/modifytasks• SeeresourceavailabilityvJobPlan• Analyze• Create• Update
• QuicklylocateallworkbasedonanydataavailableintheGantt
• Sort,filterorgroupbyanycolumn• Updateormassupdatedata• QuicklyrescheduleWorkOrders• OneClickFiltering• OneClickScheduling• Colorcodedheatmapallowsyouto
seetheimpactofreschedulingworkimmediately
• Defineweeklyordailyschedulesbasedonresourceavailability
AKWIREVisualSuiteforMaximo
Simplified!
• Quicklyfilterworktomatchcraft• Assignresourcesbasedonavailability• Assignresourcestomultiplework
ordersquickly• OneClickAssigningwithDaily
WorkSheet• Allfromthesameapplication!
• Quicklyenterresourceexceptions(vac,sick….)
• UpdatescanbeseeninvScheduler
• Seetrueavailabilityofworkforce
• Accommodatesmulti-shiftandmulti-crewexceptions
• QuicklyandeasilyentertimeinvTimeSheet• MultipleworkordersinExcellayout• Easilyandefficientlyapprovehours
PlanningandScheduling
5
EAMvsWorldClass
EAMorWorldClassMaintenance
EAMisthemanagementofassetsacrossdepartments,locations,facilitiesand/orbusinessunits.
ThegoalofEAMisfororganizationstomaximizethereturnoninvestmentfromtheirassetbasebymanagingtheassetthroughoutitslife.
• Acquisition(design,construction,commissioning)
• Operations
• Maintenance
• Decommissioning/ReplacementBenefits
• ImproveAssetUtilizationandPerformance
• ReduceCapitalCosts
• ReduceAsset-relatedOperatingCosts
• ExtendAssetLife
• MaximizeOverallAssetProductivity
• MinimizeTotalCostofOwnership
• Knowwhetheritismorecost-effectivetocontinuetomaintain,overhaulorreplaceafailingasset.
6
EAMvsWorldClass
EAMorWorldClassMaintenance
EAMisthemanagementofassetsacrossdepartments,locations,facilitiesand/orbusinessunits.
ThegoalofEAM
• ImproveReliability
• MakeBetterDecisions
• ReduceDowntime
• MoreEffectiveMaintenanceSpend
Benefits
• ImproveAssetUtilizationandPerformance
• ReduceCapitalCosts
• ReduceAsset-relatedOperatingCosts
• ExtendAssetLife
• MaximizeOverallAssetProductivity
• MinimizeTotalCostofOwnership
• Knowwhetheritismorecost-effectivetocontinuetomaintain,overhaulorreplaceafailingasset.
7
BigData?• IBMBigDataAnalytics• IoT–InternetofThings
• Watson
• Howdowegetthere?• Welldefinedprocesses• Welldefinedreportingstrategy• Correctlycaptureddata• Standardization• TeamEffort• Supportedfromthetopdown• JobPlans!
• vJobPlan• MPower
8
BigData?IoT–InternetofThings• TheInternetofThings(IoT)isthenetworkofphysical
objects,devices,vehicles,buildingsandotheritemswhichareembeddedwithelectronics,software,sensors,andnetworkconnectivity,whichenablestheseobjectstocollectandexchangedata.
• CognitiveIoT:MakingtheInternetofThingsdeliverforallofus
• Allthistogenerateaworkorder–whattoinclude?aJobPlan
9
InternetofThings
Assets
Condition
Alarm
WorkOrder
RepairReplace
IoT
JobPlan• Tasks• Labor• Parts• Hours
AnalysisAcquisitionDecommission
10
BigDataandReliabilityAReliabilityCenteredMaintenanceProcessanswersthefollowingsevenquestions:
• Whatarethefunctionsandassociateddesiredstandardsofperformanceoftheassetinitspresentoperatingcontext(functions)?
• Inwhatwayscanitfailtofulfillitsfunctions(functionalfailures)?
• Whatcauseseachfunctionalfailure(failuremodes)?
• Whathappenswheneachfailureoccurs(failureeffects)?
• Inwhatwaydoeseachfailurematter(failureconsequences)?
• Whatshouldbedonetopredictorpreventeachfailure(proactivetasksandtaskintervals=JobPlans)?
• Whatshouldbedoneifasuitableproactivetaskcannotbefound(defaultactions=JobPlans)?
Source:SAEJA1011standard
11
BigDataandReliabilityIfweunderstandourworkforceavailabilityaswellasthehoursfortheworkwehave,weshouldbeabletobetterscheduleourwork,whichbydefault,willincreaseefficiency.
• JobPlans
• Daily/Weeklyplans
• Shutdowns
• Whomakestheassignments?
• Whomanagesthework?
• Howdoestheworkgetintothetechnicianshands?
• Feedback?
• Compliancereporting?
12
JobPlansWhatisthebasicdatayouneedforaJobPlan?• Tasks(DocPalmer’sPlanningPrinciple#5)
• Crafts
• EstimatedHours
• Materials
“AproperlydesignedandexecutedPlanningandschedulingsystemcanbeoneofthemosteffectivemeansavailableinaidingreliabilityinitiativesandinculcatingreliabilitypracticesintothedailyexecutionofmaintenanceactivities.“
RickySmith,CMRP
13
JobPlans
13
14
JobPlans
WhatistheperfectJobPlan?• Onethatkeepsimproving
JobPlan
PerformtheWork
Feedback
Updatetheplan
15
JobPlans
Stats?• %ofWorkOrderswithJobPlans
• %ofPMswithJobPlans
• Industryaverage
• BestPractice
• Howdetailedshouldweget?• Wantaproblemsolvingworkforce• Carefulnottocreaterobots
16
JobPlans
BestPractices• Estimatedhoursbycraft
• Requiredcraftswithskilllevel
• Tasksandsequences(precisionmaintenance–torquespecs,belttension,tolerance,etc.)
• Materials(bytaskifpossible)
• Specialtools• Technicaldocumentation
• Safety–lockout/tagout
• Permits?
• Pictures/drawings
• Consumables
• Physicalorenvironmentalconstraints
• Traveltime?
• Contactatworksite
• Estimatedcostofthejob• Disposalandhousekeeping
17
JobPlans
BestPractices• ForwhichassetsdoIcreateJobPlans?
• ShouldIhaveoneJobPlanforeachasset?
• ShouldallworkordersincludeaJobPlan?
• WhoisdevelopingJobPlans• Qualifications• Experience• Trustedadvisor?
• Arerolesandresponsibilitiesclearlydefined?
• Dowehavedocumentedprocessesforplanning?
• Dowehaveafeedbackloop?
• Metrics?
18
JobPlans
FuturePerfect§ Wecanonlygettofutureperfectthoughcontinuous
improvement JobPlan
PerformtheWork
Feedback
Updatetheplan
19
JobPlans
19
Imagineifthisjobplanisreferencedon30PMsthataregeneratedmonthly• 30minutesplanned• 2hoursactual(1.5hourdelta)• 45hoursofunaccountedtime
monthly• 540hoursperyear(foronejobplan)• Isthishandledviaovertime?
20
PlanningandScheduling
• Itallcomesdowntoplanningandscheduling• Whatdoesittellus• Who,what,when,where,why,andhow• Resourceavailability• Rightjob,righttime,rightresources• Capturecorrectdata• Reports• Broadcasttheresults
21
ImpactofJobPlansSowhat…….whyshouldwehavejobplans?• PartofanEAMProgram
• WorldClassMaintenance
• Unplannedworkis5timesasexpensiveasplannedwork
• Improvesproductivityandassetavailability
• Reducescosts• Improvesreliability
• PAS55/ISO5500–partoftheframework
• Documentstribalknowledge(humancapital)
• Supportsdataanalyticswithmoreaccuratedata
22
Conclusion
§ Keepitsimple§ Documentyourprocesses
§ UnderstandthereisnoperfectJobPlanú Itisbettertostartwithsomethingthatcanbeimprovedupon
ratherthanwaituntilyouhaveperfectJobPlanstostart.
§ Continuousimprovementthroughfeedback
§ Definemetricsthataremeaningful§ Usethemetrics
23
Conclusion
Assets
Condition
Alarm
WorkOrder
RepairReplace
IoTReliabilityBigData
JobPlan• Tasks• Labor• Parts• Hours
AcquisitionDecommission
Related Documents
