Course Overview
- In a world striving for cost optimization and operational excellence, Maintenance Planning and Scheduling has a great role in achieving these goals. Maintenance Planning and Scheduling are the main tools for balancing operational and maintenance efficiency with operation and maintenance costs, maximizing the efficient use of work time, material, and assets, and it can increase workforce productivity from 25% to about 60% “tools in hand”.
- Richard D. Palmer said in his handbook which is a main reference for Maintenance Planning and Scheduling: “One cannot discuss maintenance planning without first considering an overall perspective of maintenance itself”. Therefore, the course will start with explaining the main maintenance aspects such as definition, where is maintenance in the asset lifecycle, main types/strategies and their advantages/disadvantages, techniques, technologies, best practices, cost, spare parts, KPIs, Excellence, etc.
- The course will explain how to build an effective maintenance planning function to play its great role in planning, scheduling, and coordinating maintenance work, this will cover the main relevant aspects such as: Maintenance Planning and Scheduling definitions, objectives, benefits, business processes, roles and responsibilities, techniques, tools, plans, methodologies, KPIs, etc.
Course Objectives:
- To give a broad understanding of maintenance and its relevant aspects
- To help understand how to select the most cost-effective maintenance strategy for each asset to control its risks and costs
- To give a global view of the importance, objectives, and benefits of the maintenance planning and scheduling process for saving time, cost and efficient utilization of the maintenance resources to maximize the productive time of the manpower
- To explain the fundamentals of planning and scheduling such as concepts, processes, tools, techniques, methodologies, roles and responsibilities, KPIs, analysis, reporting, etc.
- To explain the important role and functions of the Computerized Maintenance Management System (CMMS) as a main Maintenance Planning and Scheduling tool
- To explain in detail the planning, scheduling, and work management processes including:
work identification and prioritization, creating work requests/work orders, quality control of work requests and data, work packaging, scheduling regular meetings, materials and logistics preparation, work coordination, resources preparations and effective utilization, safety aspects of work execution, proper work orders completion, backlog definition and management, maintenance per- formance measuring (KPIs), work orders closing, history data analysis for enhancement and closing the loop. - To highlight the importance of Spare parts and Inventory Management and Control
- To give an overview of Shutdown Management as an important part of Maintenance Planning and Scheduling work
- To highlight the types of KPIs (leading and lagging), main maintenance and maintenance planning KPIs, and benchmarking against relevant world-class best practices
Specially Designed For:
This course is relevant to mid-career professionals and senior managers from varied disciplines including:
- Maintenance Planning (Planners, Schedulers, Engineers, Leaders, and Managers)
- Maintenance (Engineers, Supervisors, Section Leaders, Team Leaders, and Mangers)
- Reliability (Engineers, Section Leaders, Team Leaders, and Managers)
- Integrity (Engineers, Section Leaders, Team Leaders, and Managers)
- Operation (Engineers, Section Leaders, Team Leaders, and Managers)
Course Outline:
DAY ONE
Understanding Maintenance First
- Introduction
- Where is Maintenance in the Big Picture?
- Main Maintenance Types and Strategies
- Reactive Maintenance
- Run to Failure Maintenance
- Corrective Maintenance
- Preventive Maintenance (PM)
DAY TWO
Understanding Maintenance (cont.), Methods and Tools in Maintenance & Understanding Maintenance Planning and Scheduling
- Condition Based Maintenance (CBM)
- Predictive Maintenance (PdM)
- Maintenance Strategy Selection Methodology
- Asset Criticality Assessment/Analysis as an example of the Maintenance Strategy selection tools
- Understanding Maintenance Planning and Scheduling
- Definitions
- Difference between Planning and Scheduling
- Main Objectives of Maintenance Planning & Scheduling
DAY THREE
Maintenance Planning and Scheduling
(cont.), CMMS & Work Management
- Maintenance Planning and Scheduling Process
- The Six Maintenance Planning Principles
- Role of the Maintenance Planner
- The Six Maintenance Scheduling Principles
- Role of the Maintenance Scheduler
- Necessary Elements for Planning & Scheduling
- Planning System Necessities
- Tools Necessary for Effective Maintenance Control System
- Computerized Maintenance Management System (CMMS) as a main Tool for Maintenance Planning, Scheduling, and Work Control
- CMMS Objectives and benefits
- CMMS main modules and functions
- CMMS Failure Codes
- Work Management and Control through the Work Order System
DAY FOUR
CMMS, Work Management (continued.) & Spare Parts Management
- Backlog Management (through the Work Order System)
- Standardized Maintenance Work Management Process
- Step-1 Work Identification and Prioritization
- Step-2 Work Planning (including Job estimating methods)
- Step-3 Work Scheduling
- Step-4 Work Execution
- Step-5 Completing the Work
- Step-6 Review, analyze, and improve
- (wrench time, Schedule compliance, etc.)
- Spare Parts Management and Optimization
- MRO Spares Management and Control
DAY FIVE
Spare Parts Management (continued.), Project Management, Key Performance Indicators (KPIs), and Benchmarking
- Planning, Scheduling, and Materials Management
- Spare parts procurement process
- Basics of inventory management
- Project Management Principles and Practices
- Bar Charting Plans and Activities
- Critical Path Method (CPM)
- Tracking Plans and Progress with Tracking Bar Chart and Critical Path
- Key Performance Indicators (KPIs)
- KPIs definition and Objectives
- Leading and Lagging KPIs
- Types of Planning and Maintenance Key Performance Indicators (KPI)
- Examples of Important Key Performance Indicators (KPIs)
- Benchmarking against the Industry’s Best Practices
- What is Benchmarking?
- What are the objectives of Benchmarking?
- Examples of world-class benchmarks