Maintenance planning and scheduling : streamline your organization for a lean environment

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Title:

Personal Author:

Kister, Timothy C.

Publication Information:

Burlington, MA : Elsevier Butterworth-Heinemann, 2006

ISBN:

9780750678322

Subject Term:

Plant maintenance -- Planning

Production management

Added Author:

Hawkins, Bruce

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010104087	TS192 K57 2006	Open Access Book	Book	Searching... Unknown

This is a hands-on reference guide for the maintenance or reliability engineer and plant manager. As the third volume in the "Life Cycle Engineering" series, this book takes the guiding principles of Lean Manufacturing and Maintenance and applies these concepts to everyday planning and scheduling tasks allowing engineers to keep their equipment running smoothly, while decreasing downtime. The authors offer invaluable advice on the effective use of work orders and schedules and how they fit into the overall maintenance plan. There are not many books out there on planning and scheduling, that go beyond the theory and show the engineer, in a hands-on way, how to use planning and scheduling techniques to improve performance, cut costs, and extend the life of their plant machinery.

List of Figures	p. xi
List of Tables	p. xv
Acknowledgement	p. xvii
1 Historical View of Maintenance	p. 1
1.1 Pure Reactive	p. 3
1.2 Limited Proactive Applications	p. 5
1.3 Birth of Real Maintenance	p. 6
1.4 Military Takes the Lead in Maintenance	p. 10
1.5 Long Journey to Lean Thinking	p. 12
1.5.1 Lean Spills Over to Maintenance	p. 15
1.5.2 Maintenance Operation Refinements	p. 16
2 The Plant/Facility Lean Environment	p. 19
2.1 Lean Origins and Definitions	p. 19
2.2 Lean Organization: Elements and Practices	p. 22
2.2.1 Current State	p. 25
2.2.2 Future State	p. 26
2.3 Lean Maintenance Operations	p. 28
2.3.1 Fundamentals of Total Productive Maintenance	p. 29
2.3.1.1 Work Execution	p. 33
2.3.1.2 Planning and Scheduling	p. 34
2.3.1.3 Reliability Engineering	p. 34
2.3.2 Lean Refinements	p. 35
2.3.2.1 Reliability Excellence	p. 35
2.3.2.2 Teams and Teamwork	p. 36
2.3.2.3 New Roles for Managers and Supervisors	p. 38
2.3.2.4 Organizational Focus	p. 38
2.3.2.5 Expanded Education and Training	p. 39
2.3.2.6 Maintenance Optimization	p. 39
2.3.3 Lean Maintenance: Prerequisite of the Lean Plan/Facility	p. 41
3 Governing Principles and Concepts of Lean Maintenance	p. 42
3.1 Lean Maintenance Governing Principles and Concepts	p. 43
3.1.1 Vision and Mission	p. 45
3.1.2 Strategic Plans, Goals and Targets	p. 46
3.2 Operations and Maintenance	p. 48
3.2.1 Operations Maintenance-A Partnership with Two-Way Responsibilities	p. 48
3.2.2 A Lean Mandated Marriage	p. 51
3.3 Why Plan?	p. 58
3.3.1 Advantages of Maintenance Planning	p. 58
3.3.2 Objectives and Goals of Maintenance Planning	p. 61
4 Origins of the Maintenance Planner	p. 63
4.1 In the Beginning	p. 63
4.2 Developing Standard Practices	p. 65
4.2.1 Basic Process	p. 65
4.2.2 Manufacturing's Influence	p. 70
4.2.2.1 Accommodating a Varying Workload	p. 71
4.2.2.2 Resources, Resources, Resources	p. 74
4.2.3 Appearance of Balance	p. 75
5 Organization Alternatives	p. 78
5.1 Styles for Organizing Maintenance Operations	p. 80
5.1.1 Style Variations	p. 81
5.1.1.1 Trade Organization	p. 81
5.1.1.2 Area Organization	p. 83
5.1.1.3 Production Department Maintenance	p. 84
5.1.1.4 Joint Trade and Area Organization	p. 87
5.1.1.5 Contract Maintenance - Partial or Total	p. 88
5.1.1.6 Organization by Work Type	p. 90
5.1.1.7 Combination Styled Organization	p. 92
5.1.2 Total Productive Maintenance	p. 95
5.1.3 Reliability-Centered Maintenance	p. 98
5.1.3.1 Incorporating Work Planning	p. 104
5.1.3.2 Planning and Scheduling: Defining the Role	p. 108
5.2 TPM-RCM-Lean Organizational Considerations and Choices	p. 109
5.2.1 Where Does the Planner Fit?	p. 111
5.2.1.1 Erroneous Thinking	p. 113
5.2.1.2 The Reality	p. 113
5.2.1.3 The Assigned Tradesperson	p. 114
5.2.1.4 The Responsible Supervisor (or Team Leader)?	p. 114
5.2.1.5 Fostering a Sense of Accomplishment	p. 116
6 Performing the Planning Function	p. 118
6.1 Principles of Planning	p. 119
6.1.1 Managing the Backlog	p. 120
6.1.2 Criticality and Prioritization	p. 122
6.1.3 The Work Order	p. 130
6.1.3.1 Work Order Types and Formats	p. 130
6.1.3.2 Work Order System and Work Flow	p. 133
6.1.3.3 Coding Work Order Information	p. 136
6.1.4 Sequence of Planning	p. 150
6.1.4.1 Job Plan Level of Detail	p. 151
6.1.4.2 The Work/Job Package	p. 154
6.1.4.3 Estimating and Work Measurement	p. 161
6.1.4.4 Planning Aids	p. 167
6.1.5 The Role of CMMS in Maintenance Planning	p. 169
6.1.6 Feedback	p. 171
6.1.6.1 Building a History	p. 178
6.2 Closing Out Work Orders	p. 181
6.2.1 Data Entry and Validation	p. 182
6.2.2 Reliability Engineering	p. 183
6.3 Lean Maintenance Planning	p. 187
7 Performing the Maintenance Scheduling Function	p. 189
7.1 Scheduling	p. 189
7.2 Organizational Considerations	p. 190
7.3 Scheduling Defined	p. 193
7.3.1 Prerequisites for Effective Scheduling	p. 195
7.3.2 Preparing Schedules	p. 196
7.3.2.1 Scheduling Practices	p. 197
7.3.2.2 Scope of Maintenance Scheduling	p. 199
7.4 Metrics-Schedule Compliance and Labor Effectiveness	p. 205
7.5 General Scheduling Considerations	p. 209
8 Special Case: Maintenance Planning and Scheduling for Maintenance Outages - The Plant Shutdown	p. 211
8.1 Planned Outages Defined	p. 213
8.1.1 Phase I: Definition	p. 213
8.1.2 Phase II: Planning	p. 216
8.1.2.1 Purchasing: Plant Shutdown Logistics	p. 219
8.1.3 Phase III: Scheduling	p. 220
8.1.4 Phase IV: Execution	p. 222
8.1.5 Phase V: Debrief and Lessons Learned	p. 223
8.2 Critical Path Method Scheduling	p. 224
9 Tips, Tricks and Avoiding Pitfalls	p. 230
9.1 Straight from the Horse's...	p. 230
9.2 Gaining Trust	p. 230
9.2.1 Maintenance Planner	p. 230
9.2.2 Maintenance Scheduler	p. 232
9.2.3 Attitudes, Practices and Methodologies for Success	p. 233
9.2.3.1 Empowerment and Areas of Responsibility	p. 233
9.2.3.1 Skill Levels and Training	p. 235
9.2.4 Tips and Tricks of Successful Planners and Schedulers	p. 237
9.2.4.1 Maintenance Planner	p. 237
9.2.5 Maintenance Scheduler	p. 239
10 Metrics: Measuring Planning and Scheduling Performance	p. 241
10.1 Planning and Scheduling Performance Indicators	p. 242
10.1.1 Labor Performance	p. 242
10.1.2 Job Planning and Scheduling	p. 243
10.2 Reliability Excellence (Rx) and the P/S Function	p. 244
10.3 Summary: Characteristics of Reliability Excellence	p. 246
11 Planning and Scheduling Fundamentals - Self-Test	p. 249
11.1 Approach	p. 249
11.2 Self-Test Question and Answer Section	p. 250
11.3 Self-Test Work Exercise Section	p. 253
Appendix A Job/Position Descriptions	p. 255
Appendix B Benchmarking and Best Practices	p. 261
Appendix C Forms, Worksheets and Checklists	p. 266
Appendix D Tutorials in Brief: Control Charts and CPM Schedules	p. 282
Appendix E Chapter 11 Self-test: Answers and Solutions	p. 294
Appendix F Glossary	p. 298
Index	p. 325

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