Professional Documents
Culture Documents
Maintenance Execution
AGENDA
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Introduction
The Importance of Maintenance Execution
Maintenance Execution process steps
Maintenance Workflow
Maintenance Events
Shutdowns Process
Worked Example (Risk Analysis)
Questions
THE IMPORTANCE OF
MAINTENANCE EXECUTION
MAINTENANCE EXECUTION
What is Maintenance Execution?
y Integrated process covering:
y
JOB SCREENING
y
SCOPING
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y
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y
Replace
Repair
Patch up
Defer work
Do nothing
PLANNING
How are you going to do the work?
y Basic requirements:
y
People
Materials
Tools
Equipment
Cost Estimate
Risk Assessment
Safety Requirements
SCHEDULING
y
y
y
y
y
EXECUTION
y
Do the work
Do the work you say you are going to do
Do it when you say you are going to do it
Like taking your car in for a service
CLOSE-OUT
Often forgotten part of process
y Record completion of each step
y Collect hours worked
y Collect history (damage, cause, activities)
y Determine costs
y Continuous learning
y
WORKFLOW
Putting it all together
MAINTENANCE WORKFLOW
Routine Work
Flow
Non Routine Work
Flow
Review and
Approve
Requests
Plan
Jobs
Authorize
Costs
Prioritize
Work
Schedule
Allocate
Jobs
and Do the
for the
Work
Next Period
Unplanned Jobs
Collect
Costs &
=
Job
Feedback
Accommodate
Interrupt
Schedule
Continuous
Improvement
Types of Work
INITIATION
Different Work Types
SAP Notification
PM Schedule
Injected Work (E&SB)
SAP Notification
For a Corrective job
Acceptance required
before work proceeds
Approval by
Maintenance Manager,
etc.
PM Schedule
Automatically
generated
Pre-Approved
Injected Work
Emergency &
Schedule Breakers
For Breakdowns
Immediate approval
PLANNING
Planned Job
Planned Jobs will
require an Estimate
Can then go off to
be Approved
Before detail
planning job, get
approval to proceed
(avoids spending
time on job that may
not go ahead)
PM Schedule
Job already planned
Breakdowns
This process shows
no planning step for
breakdowns
Best practice is to
have some
templates available
for breakdowns
SCHEDULING
WORK LOG
Planned Jobs & PM
Schedules go into
common backlog of
work
Jobs that can be
deferred are
identified
SCHEDULE
Jobs are scheduled
according to
business
requirements
Schedule for all
available hours
BREAKDOWNS
Breakdowns are not
scheduled
They get injected
during Execution
phase
EXECUTION
Daily & Weekly Schedule
Jobs are executed
according to priority
and business
requirements
Deviations from
schedule managed by
Operational Personal
Breakdowns
Breakdowns are
injected into daily
schedule
Pre-identified
backlog jobs are
deferred
Breakdown work
orders should have a
sunset clause on them
(suggest 48 hours)
HISTORY
All Jobs
Failure data added to
CMMS
Hours recorded
Update library plans
(or create new ones)
Breakdowns
Reliability analysis
Is a library plan
required?
Is a PM required?
PMs
PM data updated
Recommend that PMs
do not get
rescheduled based on
Completion Date
y
y
y
BREAKDOWNS
y
y
y
CORRECTIVE WORK
y
y
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y
SHUTDOWN STEERING
GROUP
y
y
y
y
y
SHUTDOWN CRITERIA
y
Shutdown criteria
DUR
SYN
Duration
Can only be done while equipment is
disassembled for other shutdown work
Synergies with doing work in conjunction
with other shutdown work
UTIL
HAZ
OTH
DIS
LIKELIHOOD
Extreme
High
Almost Certain
(Over 30%)
$0
$0
$0
4
Likely
(10% to 30%)
18
27
Moderate
12
$0
$0
36
34
26
$105
$96
13
21
29
33
$512
2
30
22
35
$0
37
39
$271
23
38
$0
32
10
Possible
(3% to 10%)
6
14
24
7
31
$0
28
25
20
15
$443
$539
$0
$0
$0
17
2
Unlikely
(1% to 3%)
$0
$28
$97
Moderate
High
Rare
Low
(up to 1%)
$0
$0
$0
$0
Low
Minor
Moderate
Major
Critical
<$25k
$25k - $250k
$250k - $2.5m
$2.5m - $25m
>$25m
Probability of
Event Occuring in
2005/06 Financial
Year
Safety Impact
$0
$000's
GANTT CHART
DEVELOPMENT
y
y
y
y
y
RISK ANALYSIS
y
y
y
MEETING STRUCTURE
y
Consistent meeting
times
10:00 AM Morning
Area Meeting
3:00 PM Managers
Meeting
Schedule Updates
EARNED VALUE
y
Tool for
tracking
progress
against
schedule
Quickly shows
if you are falling
behind
schedule
Forecast costs
to complete
work
SHUTDOWN
COMMUNICATIONS
y
Email is a problem
Reply All
Mass Distribution lists
Not everyone has email access
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