Jacksonville, Florida - Richard D. Palmer, PE, MBA, better known as Doc Palmer, author of the distinguished Maintenance Planning and Scheduling Handbook, joins People and Processes, Inc. as a partner to expand his participation in educating, leading, and consulting with companies on the practical implementation of successful Maintenance Planning and Scheduling (MPS) programs.
Why do we need to do Strategic Maintenance Planning?
In today's global competitive environment every manufacturer feels cost and price pressure. Performance improvement is required and it must happen immediately. As companies implement Lean manufacturing, the challenge is that the assets must perform well and maintenance must accomplish this on a limited budget.
Manufacturing and Facility maintenance organizations everywhere struggle with the challenge of providing operational capacity for their company or organization. Maintenance strives to accomplish this by increasing the reliability of the equipment or process through effective Preventive Maintenance and effective material and labor budget utilization.
I've read and seen a lot of material about advanced maintenance scheduling techniques, but the reality is that most maintenance people are still struggling with the basics.
As a former Operations/Maintenance Coordinator who was sick and tired of operating in a reactive fire-fighting mode, I understood potential benefits of proper maintenance scheduling - the challenge was getting everyone on the same page. Industry experts suggest that in order to move from reactive to proactive maintenance, at least 80% of the work should be planned on a weekly basis and compliance to this schedule should be at least 90%.
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Empowering maintenance crews and personnel means allowing them to make decisions within their areas of responsibility. This greatly increases the quality of maintenance work. However, empowering does not mean turning each of the specialized areas of maintenance loose on its own. The maintenance process takes a coordinated team effort to master and an explicit scheduling process is necessary to advance productivity. Superior maintenance requires both empowerment and scheduling. This paper explains where and how high performing maintenance organizations utilize and leverage each concept.
Few tools are as useful to managing the maintenance workload and effectiveness as the Maintenance Backlog. In many companies today management of the maintenance backlog has been neglected. As a result they are generally drowning in their own data. A poorly managed system has a dramatic effect on the entire delivery of maintenance services.
Too many organizations neglect the benefits of a clearly defined prioritization system. Even when they realize the importance the focus is invariably at a department or functional level. I have seen organizations where there are up to three or more prioritization systems. None of which are inter-related.
As economic demands have increased and technology for maintenance has moved forward there has been an increasing demand on the time of the maintenance-planning department.
All of the work of backlog management, planning and priority targeted capacity scheduling are focused on efficient execution. To ensure that the tasks that need to be done, as per the true requirements of the plant, are done in a timely manner with as little waste of human and material resources as is possible.
As digital transformation finds its way into maintenance planning, the planner now has the ability to graduate their program from calendar to cycle-based PM's.