Why Maintenance Planning and Scheduling is important
No "Planning and Scheduling" means Poor Maintenance. Those are some of the results of poor maintenance;
- Frequent breakdowns and collateral damages, which needs more time to repair and complete replacement of equipment or spare parts.
- Increased spare parts inventory
- High Overtime, leads to frustration of the maintenance crew
- Low equipment uptime
- High maintenance and operational costs due to above reasons
- Safety issues
What is Planning
- Scope of work: the details of WHAT to be done and HOW
- Duration : how long each task/job will take
- Who: which crafts or individuals will perform that job
- Other resources: parts, materials and special tools are required to do that job
- Safety first : focusing Safety Concerns, making risk assessment and preparing of required work permits
- Getting and reviewing feedback from executed job.
- The feedback consists of any problems, plan changes, or other helpful information so that future work plans and schedules might be improved. The planners ensure that feedback information is properly stored and filed to improve the future work plan.
- Keeping records and developing a good equipment history
Purpose of Planning
The purpose of planning is to learn from previous experience/past/history. Job plans are head starts based on what we have learned previously. Planners collect feedback from Maintenance Crew. These feedbacks include good ideas to implement for next time when maintenance crew works on the same equipment. Planners updates history files with these feedback and continually improve existing job plans.
What is Scheduling
- the details of WHEN and WHO
- the timing of work and when this work will be done
- Reviewing the backlog
- Sorting jobs by priority
- Scheduling for ALL available man hours
- Coordinating jobs with the supervisors, production and other related departments
- Tracking work progress
- Developing the weekly and the daily maintenance plan
Scheduling is built on the foundation of good planning: Estimated Duration, the requirement and availability of manpower, parts and special tools are the basis used to effectively schedule work.
Scheduling is a joint maintenance and operations activity to establish the best timing for major jobs and services. This will ensure the efficient use of maintenance resources and the least interruption of Plant Operation.
Purpose of Scheduling
- Schedule the maximum work, safely, with the available internal resources.
- Schedule according to Priority rules, with the highest priority work orders scheduled first.
- Schedule the maximum number of PM jobs when due.
- Safely, effectively and maximum utilization of own labour - Minimize the use of contract and outside resources.
Benefits of Maintenance Planning and Scheduling
Increasing Wrench Time ;
- Minimize the loss time by good preparation, ensuring special tools, equipment and other requirements are in place and the crews are available.
- Minimize the movement of resources between areas
- Implement the better ways of doing job by using "lessons learned" history from planning (remember "Purpose of Planning")
Increasing the maintenance department’s ability to complete work orders effectively, efficiently and safely.
And as a result, achieving "Cycle of Improvement" ;
- Completing more work is essential because any “additional work" that a maintenance crew completes is a proactive work.
- The “additional” proactive work and the systematic learning from past/previous work that planning applies to subsequent work, eventually increases “the quality of work”.
- “Better quality of work” leads to higher MTBF
- Higher MTBF reduces the reactive work
- Reduced “reactive works” frees up maintenance forces to do more proactive work.
- And return to Step1