MAINTENANCE MANAGEMENT

1. PLANNING

1.1. The work order

1.2. Bill of material

1.3. Purchase requisition

1.4. Necessary drawing

1.5. Labor planning sheet including standard times

1.6. All data needed prior to scheduling and releasing the work order

2. PLANNING PROCEDURES

2.1. Determine the job content

2.2. Develop work plan

2.3. Establish crew size of the job

2.4. Plan and order part and material

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

2.6. Assign workers with appropriate skills

2.7. Review safety procedures

2.8. Set priority for all maintenance work

2.9. Assign cost account

2.10. Complete the work order

2.11. Review the backlock and develop plans for controlling it

2.12. Predict the maintenance load using effective forecasting technique

3. MAINTENANCE PLANNING AND SCHEDULING

3.1. Reduced maintenance cost

3.2. Improved utilization of the maintenance workforce

3.3. Improved quality of maintenance work

4. CLASSIFICATION OF MAINTENANCE WORK

4.1. Routine maintenance

4.2. Emergency or breakdown maintenance

4.3. Design modifications

4.4. Scheduled overhaul and shutdown of the plant

4.5. Overhaul, General repair, and replacement

4.6. Preventive maintenance

5. THREE LEVELS OF MAINTENANCE SCHEDULE

5.1. Long-range(master) schedule

5.1.1. Covering a period of 3 month to 1 year

5.1.2. Based on existing maintenance work order

5.1.3. Balancing long-term demand for maintenance work with available resources

5.1.4. Sparepart and material could be identified and ordered in advance

5.1.5. Subject to revision and updating to reflect changes in the plans and maintenance work

5.2. Weekly schedule

5.2.1. Covering 1 week

5.2.2. Generated from the master schedule

5.2.3. Takes in to account current operation schedule and economic cosideration

5.2.4. Allow 10% to 15% of the workforce to be available for emergency work

5.2.5. The schedule prepared for the current with and the following one in order to consider the available backlock

5.2.6. The work orders scheduled in this week are sequenced based in priority

5.2.7. CPM and integer programming technique can be used to generate a schedule

5.3. Daily schedule

5.3.1. Covering 1 day

5.3.2. Generated from weekly schedule

5.3.3. Prepared the day before

5.3.4. Interrupted to perform EM

5.3.5. Priorities are used to schedule the jobs

6. Objective

6.1. Minimizing the idle time of maintenance workers

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

6.3. Maintaining the operating equipment

7. SCHEDULING PROCEDURES

7.1. Sort backlock work orders by crafts

7.2. Arranged order by priority

7.3. Compile a list of complited and carry over the job

7.4. Consider job duration. location, travel distance and the possibility of combining jobs in the same area

7.5. Schedule multi-craft jobs to start at the beginning of every shift

7.6. Issue a daily schedule

7.7. Authorize a supervisor to make work assignments

8. SCHEDULING TECHNIQUES

8.1. The start and finished for each job

8.2. The interdependecies among jobs

8.3. In typically includes 3 - 10 levels of priority

9. BASIC LEVELS OF PLANNING PROCESS

9.1. Long-Rang Planning

9.2. Medium-Range Planning

9.3. Short-Rang Planning