Course Methodology
The course uses a mix of interactive and hands-on techniques. Beside the brief presentations by the consultant and the participants, the thrust will be on real life work related situations to develop maintenance schedules for preventive and breakdown jobs, calculate re-order points and optimal quantities of spare parts, evaluate maintenance initiatives, and develop the right maintenance KPIs.
Course Objectives
By the end of the course, participants will be able to:
- Explain the challenges and objectives facing maintenance organizations today
- Demonstrate the importance of work order systems and use techniques for time estimations and priority assignments
- Prepare a preventive maintenance program
- Apply project management techniques to effectively manage major maintenance activities and shut downs
- Use capital budgeting techniques to evaluate maintenance capital expenditures
- Demonstrate understanding of how to maintain the optimal stock levels of spare parts to ensure operational continuity
- Prepare the right Key Performance Indicators (KPIs) s to evaluate and improve performance in maintenance
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
- Financial evaluation
- Planning and logistics theory and practice
- Performance management
- Adaptability
Objectives of maintenance
- Definition of maintenance and asset management
- Challenges and objectives of maintenance
- The modern maintenance strategy
- Maintenance windows
- Maintenance methods
- Types of maintenance
- Classification of roles in maintenance
- Customer service in maintenance
The Work Order System
- Purpose of the Work Order (WO) system
- Information collected on a WO
- Job estimating methods
- Prioritizing maintenance work orders
Preventive Maintenance (PM)
- What is Preventive Maintenance
- The importance of implementing a PM program
- Establishing schedules
- Breaking a facility into logical parts
- Developing an equipment list
- Developing equipment manuals
- Setting up inventory
- Understanding risks associated with a PM program
Planning and scheduling of major maintenance WOS and shutdowns
- The unique challenge of maintenance shutdowns
- Importance of a clear Work Order (WO) scope definition
- Work Breakdown Structure (WBS)
- Methods for building an effective maintenance database
- Critical Path Method (CPM)
- Work order crashing
- Resource scheduling and leveling
Planning and controlling maintenance materials
- Identification of inventory costs
- Considerations in inventory decisions
- How much to order: Economic Order Quantity (EOQ)
- When to order (setting min and max levels)
Controlling maintenance work
- Maintenance Key Performance Indicators (KPIs)
- Backlog indices
- Schedule compliance indices
- PM and emergency indices
- Generic maintenance indicators
The role of planning and scheduling in Performance Improvement
- Maintenance as a business process
- How scheduled maintenance can lock in waste and cost
- Drawing learning from recurring maintenance tasks
- Reviewing planned maintenance
- Dealing with the productivity challenge
- Refining maintenance policies
- Capturing learning from inspection work
