Maintenance Planning, Scheduling and Management

This course teaches the theoretical and practical aspects of maintenance strategy development, preparing detailed maintenance plans and schedules, planning and managing shutdowns, critical path analysis and effective key performance measures.

The course provides management and staff with essential maintenance management skills, gain a clear understanding of their roles, and work more effectively within a team environment.

 

Course Objectives:

Participants will gain a practical understanding and knowledge of:

• The essential principles of effective maintenance management
• Effective procedures for planning and controlling of the maintenance work flow
• Proven methodology for the development of an effective maintenance plan
• Effective scheduling of maintenance work
• Closing the management loop through effective measurement, reporting and analysis
• How reliability influences not only plant output, but also improves health, safety and environmental performance, resource optimization and cost improvement
• Identify planning and scheduling best practices and how these will contribute to work quality and reliability improvement
• Create and preserve forward work and use it for planning and scheduling resources

Certification

• A certificate of completion will be issued at the end of the course.

Course Structure

PUTTING PLANNING IN CONTEXT

• The modern maintenance strategy
• Maintenance as a business process
• The business case for planning
• The financial benefits case
• The scope challenge
• Optimizing maintenance frequency
• The value of improving maintenance efficiency
• Benefits for operations
• Benefits for the maintenance team
• Safety performance improvement
• The different levels of planning
• The pitfalls of traditional planning processes

ROLE OF THE MAINTENANCE PLANNER

• Importance of maintenance and asset management
• Objectives and types of maintenance
• Evolution of the maintenance function
• The planning process
• Types of maintenance
• Clarification of roles in maintenance
• Defining the work order system
• Setting priorities to work orders
• Establishing a preventive maintenance program
• Preventive maintenance risks

MODERN MAINTENANCE MANAGEMENT PRACTICE IN PERSPECTIVE

• Maintenance in the Business Process
• What does it looks like
• What it could look like
• Evolution in Maintenance Management
• Reactive vs. Proactive Maintenance
• World-Class Maintenance Management

MAINTENANCE POLICIES AND LOGISTICS PLANNING

• Equipment Classification and Identification
• Document Identification and Classification
• Maintenance Management Policies
• Maintenance Work Prioritization
• Maintenance Logistics Planning

FAILURE MANAGEMENT PROGRAMME DEVELOPMENT

• Failure Modes, Effects and Consequences (FMEA)
• Failure Management Policies
• Application of RCM in the Development of Failure Management policies
• Implementing Failure Management Policies
• Corrective Maintenance Planning
• Logistic Requirements Planning

WORK SCHEDULING AND CONTROL

• Development of Weekly Master Schedule
• Determine Resource Availability
• Determine Equipment Outage Requirement
• Management of the Forward Workload (Backlog)
• Weekly Master Schedule Implementation

 PERFORMANCE MEASUREMENT,

 MANAGEMENT REPORTING AND ANALYSIS

• Information and Control
• Management Levels and Information
• Performance Indicators
• Workload Performance Indicators
• Planning Performance Indicators
• Effectiveness Performance Indicators
• Cost Performance Indicators
• Management Reports

CRISIS MANAGEMENT

• What is a crisis and why the need for crisis management?
• Different types and levels of crises
• The crisis management cycle
• Preparing for crises
• Managing crises
• Post-crisis evaluation and learning

ASSETS MANAGEMENT

• The nature of assets and asset management
• Asset Management Policy, Strategy and Planning
• Managing Asset Life Cycle Decisions and Activities
• Assessing and Managing Asset Management Risks
• The Financial and Business Impact of Asset Management

DECISION MAKING SKILLS.

• Needs, Wants, and Actions
• Making Everyday Decisions
• How to appropriately involve others in decision making
• How to reduce risks inherent in decision making
• Decision- Making Tools and Resources

EFFECTIVE SHUTDOWN PLANNING AND MANAGEMENT

• Why shutdown and how often
• Management Process for Shutdowns, turnarounds and outages
• Shutdown Planning and Preparation
• Effective Shutdown Supervision
• Shutdown Completion and Review

CASE STUDIES AND GROUP DISCUSSIONS

• Troubleshooting
• Case Studies
• Summary & Review

Course Methodology

The course uses a mix of interactive and hands-on techniques. Beside the presentations by the trainer and the participants, there will be many exercises based on actual maintenance work related scenarios.

The trainee will receive an extensive reference manual, as well as case studies, while worked out solutions will be handed out to the trainees on conclusion of the training session. Throughout the training course, trainees will be encouraged to identify what they can do to enhance Maintenance Planning, Scheduling and Work Control in their organizations.