MAINTENANCE PLANNING AND SCHEDULING1.ppt

7/26/2019 MAINTENANCE PLANNING AND SCHEDULING1.ppt

http://slidepdf.com/reader/full/maintenance-planning-and-scheduling1ppt 1/31

MAINTENANCE

PLANNING AND

MANAGEMENT



Group Members

• M. Wasim Anwar UW-12-ME-B!-"1#

• $a$ru%$ &$an UW-12-ME-B!-"1'

• (a$eer A$me) UW-12-ME-B!-"2#



Planning

Planning is the process by which the elementsrequired to perform a task are determined in

advance of the job start.



• “People cannot be more productive than the system theywork in allows them to be.”

• “Proper Planning Prevents PoorPerformance.” (PPPPP)



Planning • It comprises all the functions related to the preparation

of:

1. The work order: order received by an organi!ationfrom a customer or client" or an order createdinternally within the organi!ation#

$. %ill of material: list of the raw materials" sub&assemblies" parts etc#

'. Purchase requisition: a document used as part of theaccounting process #

(. )ecessary drawings*. +abor planning sheet including standard times

,. -ll data needed prior to scheduling and releasing thework order.

• ood planning is a prerequisite for sound scheduling.



Planning Procedures

• /etermine the job content.

• /evelop work plan. This entails the sequence of

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

• 0stablish crew si!e for the job.

• Plan and order parts and material.

• heck if special tools and equipment are needed

and obtain them.

• -ssign workers with appropriate skills.



Planning Procedures

• 2eview safety procedures.

• 3et priorities for all maintenance work.

•

-ssign cost accounts.• omplete the work order.

• 2eview the backlog and develop plans for

controlling it.

• Predict the maintenance load using effective

forecasting technique.





MAINTENANCE PLANNING AND

MANAGEMENT

0ffective planning and scheduling contribute

significantly to the following:

• 2educed maintenance cost.

• Improved utili!ation of the maintenance workforce

by reducing delays and interruptions.

• Improved quality of maintenance work by

adopting the best methods and procedures and

assigning the most qualified workers for the job.



Planning and Scheduling Objectives

• 4inimi!ing the idle time of maintenance workers.

•4a5imi!ing the efficient use of work time"material" and equipment.

•

4aintaining the operating equipment at aresponsive level to the need of production in terms

of delivery schedule and quality.



Classiication o Maintenance !or"

According to Planning and SchedulingPur#oses

• 2outine maintenance: are maintenanceoperations of a periodic nature. They are plannedand scheduled and in advance. They are covered

by blanket orders.

•

0mergency or breakdown maintenance: interruptmaintenance schedules in order to be performed.They are planned and scheduled as theyhappened.



• /esign modifications: are planned and

scheduled and they depend on eliminating thecause of repeated breakdowns.

• 3cheduled overhaul and shutdowns of the plant:

planned and scheduled in advanced.

• 6verhaul" general repairs" and replacement: planned and scheduled in advanced.

• Preventive maintenance: planned and scheduledin advanced.



• -n essential part of planning and scheduling isto forecast future work and to balance the

workload between these categories.

• The maintenance management system should

aim to have over 789 of the maintenance work

planned and scheduled.



$asic Levels o Planning Process %De#end on

The Planning &ori'on(

1. +ong&rang planning: it covers a period of ' to *years and sets plans for future activities andlong&range improvement.

$. 4edium&range planning: it covers a period of 1month to 1 year.

'. 3hort&rang planning: it covers a period of 1 dayto 1 week. It focuses on the determination of allthe elements required to perform maintenancetasks in advance.



Long and Mediu)*+ange Planning

)eeds to utili!e the following:

1. 3ound forecasting techniques to estimate themaintenance load.

$. 2eliable job standards times to estimate staffingrequirements.

'. -ggregate planning tools such as linear programming to determine resource requirements.



Long*+ange Planning

sets plans for future activities and long&range

improvement.



Mediu)*+ange Planning

• 3pecify how the maintenance workers willoperate.

•Provide details of major overhauls" construction

jobs" preventive maintenance plans" and plantshutdowns.

• %alances the need for staffing over the period

covered.• 0stimates required spare parts and material

acquisition.



Short*+ange Planning

It focuses on the determination of all the elements

required to perform maintenance tasks in advance.



Scheduling

Is the process by which jobs are matched withresources and sequenced to be e5ecuted at a

certain points in time.



Scheduling

• 3cheduling deals with the specific time and

phasing of planned jobs together with the ordersto perform the work" monitoring the work"

controlling it" and reporting on job progress.

• 3uccessful planning needs a feedback from

scheduling.



+eliable Schedule Must Ta"e Into

Consideration

• - 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.

• 2ealistic estimates and what is likely to happen.

• le5ibility in the schedule.



Maintenance Schedule Can be Pre#ared at

Three Levels %De#end on The Ti)e

&ori'on(

1. +ong&range master# schedule

$. ;eekly schedule

'. /aily schedule



Long*+ange %)aster( Schedule

• overing a period of ' months to 1 year.

• %ased on e5isting maintenance work ordersblanket work order" backlog" P4" anticipated

04#.

• %alancing long&term demand for maintenancework with available resources.

•

3pare parts and material could be identified andordered in advance.

• 3ubject to revision and updating to reflectchanges in the plans and maintenance work.



!ee"l, Schedule

• overing 1 week.

• enerated from the master schedule.

• Takes into account current operations schedules and

economic considerations.• -llow 189 to 1*9 of the workforce to be available for

emergency work.

• The schedule prepared for the current week and thefollowing one in order to consider the available

backlog.• The work orders scheduled in this week are sequenced

based in priority.

• P4 and integer programming techniques can be usedto generate a schedule.



Dail, Schedule

• overing 1 day.

•

enerated from weekly schedule.• Prepared the day before.

• Interrupted to perform 04.

•

Priorities are used to schedule the jobs.



Ele)ents o Sound Scheduling

2equirements for effective scheduling:

• ;ritten work orders that are derived from a well&

conceived planning process. ;ork to be done"methods to be followed" crafts needed" spare parts

needed" and priority#.

• Time standards.

• Information about craft availability for each shift.

• 3tocks of spare parts and information on

restocking.



Ele)ents o Sound Scheduling

2equirements for effective scheduling:

• Information on the availability of specialequipment and tools necessary for maintenance

work.• -ccess to the plant production schedule and

knowledge about when the facilities will beavailable for service without interrupting

production schedule.• ;ell&define priorities for maintenance work.

• Information about jobs already scheduled thatare behind the schedule backlog#.



Scheduling Procedures %Ste#s(

• 3ort backlog work orders by crafts.• -rrange orders by priority.• ompile a list of completed and carry over jobs.• onsider job duration" location" travel distance"

and the possibility of combining jobs in thesame area.

• 3chedule multi&craft jobs to start at the beginning of every shift.

• Issue a daily schedule not for shutdownmaintenance#.

• -uthori!e a supervisor to make workassignments dispatching#.



Maintenance -ob Priorit, S,ste)

• Priorities are established to ensure that the most

critical work is scheduled first.

• It is developed under coordination with operations

staff.

• It should be dynamic.

• It must be updated periodically to reflect changes inoperation and maintenance strategies.

• It typically includes three to ten levels of priority.



Scheduling Techni.ues

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.



MAINTENANCE PLANNING AND SCHEDULING1.ppt

Documents