Maintenance Planning and Scheduling

Based on the popular text and comic, planning and scheduling improve maintenance productivity and safety, reduce costs and downtime.

Planner class for Jordan Aviation, Amin, Jordan

Maintenance work suffers from low productivity because each job requires the integration of various competencies, materials, tools, access, and specific information. Planning, coordination, and scheduling manage these thousands of details to improve productivity, improve safety, and reduce cost and downtime.

This program is designed for:

Designed for intensive maintenance environments, including mining, utilities, factories, refineries, smelters, and process plants, as well as large facilities. Titles include Maintenance planners, planners in training, supervisors, and individuals responsible for managing the planning function.

In addition to schedulers, material coordinators, and maintenance engineers, who get involved in creating job plans. There is also an advantage to having representatives from operations and stores for their perspective and input.

Our promise for this program is that your planners will be conversant with the techniques and procedures of effective planning and scheduling. They will also be trained to coordinate the maintenance schedule with production control and operations. This new understanding will lead to more effective job plans and better scheduling.

Benefits from sponsoring this course in-house:

You and your team will learn:

Well-planned, properly scheduled and effectively coordinated jobs can be accomplished

Planning and Scheduling class at Windalco, (bauxite mine) Mandeville, Jamaica

Also, a few extras like reduced parts usage and higher organizational morale (in production departments) are direct benefits.

Effective planning and scheduling also help increase the professionalism of maintenance efforts. In short, more work is completed more promptly, thereby improving customer service. It’s simple; you reduce wasted resources and save money.

Materials (one textbook, one comic book written for maintenance workers. Also, a complete workbook with supplemental materials and exercises

Virtual, Online configurations

Live, onsite

5-18 contact hours

9 A.M. to 4 P.M. with lunch and breaks

5-Day 1-hour

5-Day 2-Hour

4-Day 3-Hour

4-Day 4-Hour

3-Day 6-Hour

2-days

3- days

5-days

Can be scheduled 1,2,3 sessions per week with homework

Contiguous

Related courses: Shutdowns, Turnarounds and Outage Training 

Agenda for Maintenance Planning and Scheduling

In the following agendas:

RED – Exercise with class involvement and discussion

BLUE—Case Study from Relevant industry

All sections will include discussions, case studies, exercises, and will consist of an activity to help plan your future direction.

2-Day Course Planning and Scheduling course agenda

Day 1 Course Agenda:

Day 2 Agenda

3- Day Planning and Scheduling course agenda

Day 1 Agenda:

  • What is maintenance planning?
    • Terms we use in Planning and scheduling
    • Facing the facts
    • Why is planning essential for smooth operations?
    • What are the advantages of planning?
    • Workers are in pain from the lack of Planning
    • How to Sell Planning & Scheduling to your management and operations?
    • Specifically, what provides the ROI (Return on Investment)?
  • Where does Planning fit into Good Maintenance Practices?
    • Reactive Maintenance
    • Typical worker’s day
    • Understanding the Nature of Maintenance Activities.
    • Safety
  • Maintenance Management
    • Maintenance Workflow
    • Where does work come from
    • Job control
    • Costs Iceberg
  • Backlog and backlog management
    • What is in the backlog
    • Backlog to control the maintenance effort
    • Consequences of backlog size and change

Planning and Scheduling for the Saudi Engineering Council in Dammam, Saudi Arabia

  • Work orders in support of Planning and scheduling
    • All the reasons and types
    • Prioritization
    • Questions to answer
    • Auditing work orders
    • Training in completing work order preparation.
    • A short discussion of the workflow with a job control function
  • Risk, safety, and health
    • ISO 32000
    • Risk, Threat matrix
    • Safe work process
    • Safety risk list
    • How to do JSA for planning exercise
  • A complete description of the planner’s job.
    • Time spent in a typical planner/scheduler’s day
    • Roles and Responsibilities
    • Planner’s qualifications (skill sets)
    • Why can’t supervisors plan for themselves?
    • Planner qualifications

 Planning Class at Windalco, Mandeville, Jamaica

  • What are the conditions necessary for effective Planning?
    • Specific areas include storerooms, PM programs, planner Libraries, supervision, and high-level sign-off.
    • Steps in setting up Planning/scheduling
    • Steps in an ongoing planning/scheduling environment
    • Flow chart of the weekly planning process

This chart is called the Planner Thought Process. We use it to teach people to plan maintenance jobs.

  • How to plan maintenance work
    • What are the steps in effective Planning?
    • The complete planning processes.
    • Estimating, Crew Size & Manpower Requirements.
    • What are the contents of a complete planned job package?
    • Planner’s checklist
    • Planning provides* (Important)
    • Emergency planning
    • Hints from the trenches
    • Detailed, step-by-step -how to plan maintenance jobs
    • Planning Exercise using estimates

o   Planning Exercise construction estimates

·         Complete the Planning questionnaire so that participants can evaluate their current planning operation against competent and world-class organizations.

·         Evaluate the gap between what is happening and what would serve the organization’s long-term interests.

Day 2 Agenda

Maintenance Scheduling

·         Scheduling (how is it different from Planning)

·         Ready Backlog                                                           

o   Validate backlog

o   Rules to validate

o   Common problems                               

  • Work Program
    • Calculating available hours from maintenance workers includes worksheets and exercises.
  • How and why to prepare the Maintenance Calendar
    • 52-week PM schedule
  • The coordination meeting between operations and maintenance
    • Discussions and deliverables from the meeting
    • Agenda Example
    • Creating the worklist
    • Barriers to coordination
  • Scheduling
    • How to create a schedule
    • Calculating available hours for maintenance workers.
    • Validate backlog
    • Coordination with Operations and Coordination meeting
    • Choose jobs based on need and available resources
    • Schedule a shop exercise for four crafts and 14 personnel for a week.
  • The way productivity increases (why does P/S work)
    • Specific examples from the exercise –reworking the ready backlog
    • A detailed look at productivity
  • Scheduling uncovers problems in your operation

              

  • Jobs of the scheduler
    • Others sometimes carry out the scheduler’s tasks
    • How to use CMMS to Aid Planning and Scheduling.

 

  • Job execution and feedback with job closeout and follow-up

 

Day 3 Agenda

  • Metrics and KPIs
    • Schedule compliance, Performance, Effectiveness
    • Direct Measures of Planning Effectiveness
    • Scatter charting                        
    • Indirect Measures of Planning Effectiveness
  • Complete the scheduling and coordination questionnaire so that participants can evaluate their current planning operation against competent and world-class organizations.
  • Routine Maintenance Gap analysis
Wrap-Up Session
•                     The final session reviews the topics covered throughout the class
•                     Questions and discussion

5-Day Course Planning and Scheduling course agenda
(The 5-day version includes elements of the Shutdown class)

Agenda

Basics of Shutdowns, Turnarounds, and Outages

Day 1

What is maintenance planning?

Where does Planning fit into Good Maintenance Practices?

Maintenance Management

Review of current practices

Backlog and backlog management

Work orders in support of planning and scheduling

Short discussion of the workflow with a job control function.

What are the conditions necessary for effective planning?

Day 2

Review of current practices

Work Program

How and why to prepare the Maintenance Calendar

The coordination meeting between operations and maintenance

Scheduling

Day 3 Agenda

The way productivity increases (why does P/S work)           

Scheduling uncovers problems in your operation

Jobs of the scheduler

PM systems to support Planning and scheduling

Job execution and feedback with job closeout and follow-up 

Metrics and KPIs

Complete scheduling and coordination questionnaire so that participants can evaluate their own current planning operation against competent and world-class organizations.

Day 4

Planning multiple jobs

Introduction to Project Management Techniques

Day 5

Schedule and execution essentials

  • Final Gap analysis
  • Concrete steps to take

Training options :

We are flexible about your specific needs for outcomes from the course.

Option 1
Option 1

The most basic way is to present a standard course after a brief email conversation about goals and objectives. The courses are tried and tested and have been used to good effect worldwide in many maintenance situations.

Option 2
Option 2

The second and most common option involves a one-day site visit before the class. This visit allows me to add examples from your facility, adjust the verbal presentation to suit your needs, meet some key players, and see some of the unique problems you face.

Option 3
Option 3

involves a more extensive site visit (to be defined) a few weeks before the class. This extra time allows me to customize and add examples from your facility and adjust the verbal presentation to suit your needs. It is always good to meet some of the key players and see for myself some of the unique problems you face.

Option 4
Option 4

The third option is to conduct a maintenance audit survey that looks at all the aspects of maintenance, evaluates areas where improvements are possible, and slanting the training to the competencies needed to implement the upgrades uncovered in the survey.

more details about this course