Maintenance Planning and control
Course Code: EM40
►Course Objective
- 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.
- planners responsible for maintenance planning.
- scheduling and control activities.
- Divisional managers.
►Course Outline
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
- The design of financial models for forecasting and decision-making
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