Basic Principles of maintenance planning

Basic Principles of maintenance planning

Maintenance Planning

Effective planning and scheduling contribute significantly to the following:

•         Reduced maintenance cost.

•         Improved utilization 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 Objectives

•         Minimizing the idle time of maintenance workers.

•         Maximizing the efficient use of work time, material, and equipment.

•         Maintaining the operating equipment at a responsive level to the need of production in terms of

delivery schedule and quality.

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Classification of Maintenance Work According to Planning Purposes

·        Routine maintenance: are maintenance operations of a periodic nature. They are planned and scheduled and in advance. They are covered by blanket orders.

·        Emergency or breakdown maintenance: interrupt maintenance schedules in order to be performed. They are planned and scheduled as they happened.

·        Design modifications: are planned and scheduled and they depend on eliminating the cause of repeated breakdowns.

·        Scheduled overhaul and shutdowns of the plant: planned and scheduled in advanced.

·        Overhaul, general repairs, and replacement: planned and scheduled in advanced.

·        Preventive maintenance: planned and scheduled in advanced.

·        An essential part of planning and scheduling is to forecast future work and to balance the workload between these categories.

·        The maintenance management system should aim to have over 90% of the maintenance work planned and scheduled.

Planning Procedures

•         Determine the job content.

Develop work plan. This entails the sequence of the activities in the job and establishing the best methods and procedures to accomplish the job.

•         Establish crew size for the job.

•         Plan and order parts and material.

•         Check if special tools and equipment are needed and obtain them.

•         Assign workers with appropriate skills.

•         Review safety procedures.

•         Set priorities for all maintenance work.

•         Assign cost accounts.

•         Complete the work order.

•         Review the backlog and develop plans for controlling it.

•         Predict the maintenance load using effective forecasting technique.

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Basic Levels of Planning Process (Depend on The Planning Horizon)

1.     Long-rang planning: it covers a period of 3 to 5 years and sets plans for future activities and long-range improvement.

2.     Medium-range planning: it covers a period of 1 month to 1 year.

3.     Short-rang planning: it covers a period of 1 day to 1 week. It focuses on the determination of all the elements required to perform maintenance tasks in advance.

1.Long Range Planning

Needs to utilize the following:

1.     Sound forecasting techniques to estimate the maintenance load.

2.     Reliable job standards times to estimate staffing requirements.

3.     Aggregate planning tools such as linear programming to determine resource requirements. sets plans for future activities and long-range improvement.

2. Medium-Range Planning

•         Specify how the maintenance workers will operate.

•         Provide details of major overhauls, construction jobs, preventive maintenance plans, and plant shutdowns.

•         Balances the need for staffing over the period covered.

•         Estimates required spare parts and material acquisition.

3. Short-Range Planning

It focuses on the determination of all the elements required to perform maintenance tasks in advance.

Assessing  required  maintenance  tools  and  skills  required  for  efficient  maintenance  of equipment.

Assessing required skills required for maintenance personnel.

Reviewing personnel transfers to and from maintenance organizations assessing and reporting safety hazards associated with maintenance of equipment.

Assessing required skills required for maintenance personnel.

Reviewing personnel transfers to and from maintenance organizations assessing and reporting safety hazards associated with maintenance of equipment.