Course Methodology

The course uses a mix of interactive and hands-on techniques. Beside the brief presentations by the consultant and the participants, there will be many individual and group exercises based on actual maintenance work related scenarios. Given that the course is a certified one, there will also be a test at the end of the course.

Course Objectives

By the end of the course, participants will be able to:

• Apply the latest concepts and techniques needed to effectively plan, schedule and control maintenance activities
• Use project management techniques to manage major maintenance activities and shut downs
• Demonstrate an understanding of how to maintain the optimal stock levels of spare parts to ensure operational availability
• Prepare the right maintenance KPIs to evaluate and improve the performance of critical maintenance processes in their department
• Select capital budgeting techniques to evaluate maintenance capital expenditures
• Relate and communicate with others to achieve the desired goals

Target Audience

Managers, supervisors and planners responsible for maintenance planning, scheduling and control activities.

Target Competencies

• Maintenance theory and practice
• Maintenance work processes
• Project management
• Planning and logistics theory and practice
• Performance management
• Financial evaluation
• Influencing and communicating

Putting planning in context

• The modern maintenance strategy
• Maintenance as a business process
• The business case for planning
• The financial benefits case
• The scope challenge
• Optimising maintenance frequency
• The value of improving maintenance efficiency
• Benefits for operations
• Benefits for the maintenance team
• Safety performance improvement
• The different levels of planning
• The pitfalls of traditional planning processes

Role of the maintenance planner

• Importance of maintenance and asset management
• Objectives and types of maintenance
• Evolution of the maintenance function
• The planning process
• Types of maintenance
• Clarification of roles in maintenance
• Defining the work order system
• Setting priorities to work orders
• Establishing a preventive maintenance program
• Preventive maintenance risks

Planning major maintenance work and shutdowns

• The unique challenge of shutdowns
• A model of excellence of shutdown preparation
• Scope of work and activities
• Work Breakdown Structure (WBS) requirements
• Setting and using maintenance standards
• Planning and scheduling constraints
• The critical path method
• Forward and backward scheduling
• Manpower planning
• Resource planning histograms
• Planning the preparation and strategic work

Controlling maintenance work

• Types of control and control documentation
• The use of Key Performance Indicators (KPIs) that count in maintenance
• Sources of data for KPIs
• Examples of maintenance KPIs

Driving maintenance performance

• Drawing learning from recurring maintenance tasks
• Refining maintenance policies
• Learning from reviewing planned maintenance
• Capturing learning from inspection work
• Scope optimisation
• The 3R’s process
• Dealing with the productivity challenge
• Labour utilisation and tool time
• The driven DILO process
• The importance of measuring productivity
• Challenge planning – the next step?
• The 5T’s
• SMED analysis

Dealing with maintenance colleagues, management and users

• The importance of communication skills
• Possible communication barriers
• Reasons we face conflict
• Managing conflicts effectively
• Styles in managing conflict