Audel Managing Maintenance Planning and Scheduling
A good plan is good for business\ Breakdown maintenance still accounts for much of the time maintenance workers put in. Too often, the result is lost revenue, excessive downtime, and poor-quality repairs. This convenient, practical guide shows you how to develop a comprehensive planning and scheduling effort to ensure all resources are available when they are needed. You'll discover how to gather supportive data and build plans that will help you control maintenance costs and equipment...
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Brown (a principal of New Standard Institute, Inc.) offers a primer on the management of industrial maintenance planning and scheduling. Chapters discuss defining the level of maintenance; job estimation methods; planning and estimating electrical work; understanding preventive and predictive maintenance; scheduling methods; planning for shutdowns, turnarounds, and outages; gathering data for maintenance performance indices; using indices to measure performance; and using multiskill training. Annotation © 2004 Book News, Inc., Portland, OR
About the AuthorxIntroductionxiChapter 1Defining the Level of Maintenance1Era of Business Management Theories1The Movement to Reliability and Availability3Planned Maintenance under Attack5Maintenance Work Performed during Maintenance Custody (Shutdowns)7Maintenance Performed during Production Custody8The Maintenance Budget9Setting Goals Based on the Budget9The Purpose of a Work Order System11Objections to a Formal Work Order System12Work Order Categories12Generating a Work Order15Cost Data17Planning and Scheduling21The Planning and Scheduling Profession21Planning Defined23Resources23Scheduling Defined25Resource Constraints26Summary27Chapter 2Estimating Methods31Judgment versus Guessing31How Job Estimates Are Used in Maintenance32Planning and Estimating Methods34Construction Planning and Estimating35Methods Time Management (MTM)44The Planning Thought Process50Estimating Using Past Performance65The Estimating Learning Curve71Work Packages73Factors Affecting the Accuracy of an Estimate74Planning Conditions74Direct Planner Problems76Insufficient Time77Assigning the Crew Size to a Job77Parts and Material Requirements77Kits78Tagging Parts78Saving Space79Ordering Parts80Special Orders80Job Site Deliveries80Handling Delays in an Estimate80Summary84Chapter 3Planning and Estimating Electrical Work87Background87Understanding the Single-Line Diagram88Branch Circuit Checklist92Feeder Checklist93Conduit Installation Time94Pulling Cables in Conduit94Mounting Lighting Panels95Motor and Motor Control Checklist95Time Estimates for Mounting a Motor96Estimating Time to Connect a Motor96Medium Voltage (601 to 35,000 Volts) Feeder Checklist97Estimating Troubleshooting and Repair Jobs97Identifying and Estimating Maintenance Work During an Electrical Shutdown99Summary99Chapter 4Understanding Preventive and Predictive Maintenance101Examining Preventive Maintenance (PM)102Writing a PM Procedure104Procedure Elements106PM Development Worksheet107Sources of PM Procedures109Evaluating PM Procedures112Evaluating PM Programs112Unrecognized Benefits of PM113Other Options and Pitfalls to Avoid114PM Development Teams114Computerized PM Systems115Understanding Predictive Maintenance (PDM)115Spectrum of Predictive Maintenance116Vibration PDM Programs118Defining Vibration Velocity Limits119Lubrication Analysis121Stress Crack Detection (Acoustic Emission)124PDM Success Stories and Failures124Correcting Common Problems126The Four Ts of Correction127Summary128Chapter 5Scheduling Methods131Prioritizing Maintenance Work131Classification132Requested Completion Date132Schedule Priority133Using a Maintenance Backlog135Controlling Backlog135Invalid Backlogs136Calendars136Scheduling with a Plotted Backlog137Allocation Scheduling Method140Weekly Schedules146Daily Schedules148Auditing a Completed Daily Schedule150Sample Maintenance Daily Scheduling Procedure151Scheduling in Computerized Maintenance Management Systems (CMMS)151Key Work Order Scheduling153Limitations to CMMS Scheduling153Priority Numbering Systems154Equipment List154Equipment Priority155Condition Priority155Safety or Environmental Modifier156Overall Priority156Modifications to Priority Numbering Systems158Summary158Chapter 6Planning for Shutdowns, Turnarounds, and Outages161Preparing for a Shutdown161Job Input162Shutdown Organization164Execution Reporting164Turnaround Checklist165Critical Path Method (CPM)169Logic Network Conventions170Precedent Logic171Salami Sandwich Project172Finding the Critical Path173Earliest Completion Time, Latest Completion Time, and Float173Piping System Replacement Project174Time Domain Logic Network178Reducing Project Time178Project Duration versus Project Cost179Load Leveling and Project Constraints180Computerized CPM Programs182Shutdown Tips183Summary183Chapter 7Gathering Data for Maintenance Performance Indices187Completed Work Data188Total Completed Labor Hours189Emergency Work Orders and Labor Hours189PM Labor Hours Completed189Overtime190Backlog Data190Backlog Hours190Planner's Backlog191Crew Week191Schedule Data191Scheduled Hours191Actual Hours of Scheduled Work Completed192Number of Days on the Schedule192Base Cost Data192Cost of the Maintenance Hour192Total Maintenance Costs194Cost by Equipment195Total Contract Costs195Cost of Production195Book Value of Facility195Other Data196Downtime Hours196Equipment Availability197Inadequate Repairs197Corrective Action Work Derived from the PM Effort198Equipment Reliability Data198Summary198Chapter 8Using Indices to Measure Performance201The Need for More Than One Index201Backlog Indices204Backlog Age207Schedule Compliance209Estimating Accuracy210Evaluating Actual versus Estimate212Possible Overstaffing212Bad Labor Estimates213Lack of Parts213Equipment Still Running213Poor Work Performance213PM and Emergency Indices214Other PM Indicators216Overtime216Productivity Indicators217Ratio of Maintenance Labor Costs to Maintenance Material Costs218Maintenance Cost per Unit of Production218Actual Maintenance Cost Compared to Budget Costs218A Discredited Index219Managing with Indices219Case Study: What's the Problem Here?220Basic Maintenance Reporting220Balance Sheet223Performance Indices223Graphical Presentation224Summary225Chapter 9Using Multiskill Training227Understanding Multiskilling228Multiskilling Pitfalls229Successful Multiskilling Programs230Identifying Friction Areas and Multiskill Opportunities231Potential Friction Areas231Identifying Potential Gains233Defining the Training233Negotiating the Multiskilling Program234Implementing the Skills234Multiskilling--A Win-Win Effort234Summary236Appendix AIdentifying Electrical Work to Be Performed During a Shutdown237Electrical Shutdown Checklist240Months and Weeks Prior to the Shutdown241During the Shutdown247Glossary255Index267
