Maintenance Management Level 4

Maintenance Planning and Scheduling for Routine Maintenance and Shutdowns 3-day

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 better job plans and more effective scheduling.

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

• more efficiently
• at lower cost
• with fewer disturbances to operations
• with higher quality (reduce variability in your process),
• greater safety,
• improved morale (by providing greater job satisfaction),
• increased longevity of equipment.

A few extras like reduce parts usage and higher organizational morale (in production departments) are also direct benefits of planning and scheduling.

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

Day 1 Course Agenda

• What is planning and why plan maintenance jobs?
• How to Sell Planning & Scheduling to your management and operations? Specifically where does the ROI (Return on Investment) come from with planning?
• Understanding the Nature of Maintenance Activities. Where does Planning fit Into Good Maintenance Practices.

Design of work order systems, auditing work orders and training in completing work order preparation. Short discussion of the work flow with a job control function.

• Complete Planning questionnaire so that participants can evaluate their own current planning operation against competent and world class organizations.
• Complete description of the planner’s job.
• What are the conditions necessary for effective planning? This section includes a discussion of the institutional systems necessary for successful planning and scheduling. Specific areas include storerooms, PM programs, planner Libraries, supervision and high level sign-off.
• What are the steps in effective planning?
• The complete planning process. Workshop exercise in specific job planning. This is called micro-planning (job by job).
• Estimating, Crew Size & Manpower Requirements. Estimation and slotting
• What are the contents of a complete planned job package? The contents are based on the complexity, hazard, experience and size of the job.

Day 2 Course Agenda

• Calculating available hours from maintenance workers. Given your straight time year how many hours are actually available for maintenance scheduling. Includes work sheets.
• Complete scheduling and coordination questionnaire so that participants can evaluate their own current planning operation against competent and world class organizations.
• Scheduling Maintenance Work. Coordination with Operations and Coordination meeting. Includes a generic agenda for the weekly coordination meeting.
• One task at the coordination meeting is Job Loading until available hours are used up. We will perform a job loading exercise in this section.
• After the jobs are loaded the next step is to create a credible schedule that takes all the constraints into account.
• Job execution and feedback with job closeout and follow up
• How to use CMMS to Aid Planning and Scheduling.
• Metrics and Benchmarking Planning and Scheduling includes both direct and indirect measures of maintenance effectiveness.

Course Agenda for Day 3

introduces a new topic: Application of Planning and Scheduling for Maintenance Shutdowns

This part of the class is 85% concerned with the time before the first spade of dirt is moved. The remaining 15% is execution tactics to keep the project on course. In this course the common phrases shutdown, outage and turnaround are used interchangeably.

All attendees will receive a copy of Managing Maintenance Shutdowns and Outages

A few things your staff will learn:

Day 3 Develop checklist of everything to consider before the shutdown and when to consider it.

• How to prepare your own customized checklist so everything is remembered.
• When and how to say no to added work
• Know how to use Gantt, CPM and PERT charts
• What documents to save and how to organize them
• Know how to break a job into activities
• How to set up the shutdown team
• How to account for everything that goes into an outage or shutdown
• Where to look for help on estimates
• Find out what shifts structures to use and how much they really cost.
• Checklist of specific safety risks protecting your workers
• How to control a shutdown
• How to insure lessons learned are really learned
• What to do if a shutdown has gotten into trouble
• How to calculate the critical path (even if you don’t have software).
• How to know which work orders you should work on first.
• How to evaluate the effectiveness of your current shutdown effort.
• Where to find some great Internet based resources.
• Know how to manage risk on any project
• How to learn from your mistakes and institutionalize lessons learned
• How to get the most from your existing Project Management software
• How to set-up safety program for your shutdowns

In this one day section you will save money and time on your next shutdown.

Our promise for this program is that you will have a new and deeper understanding of how to effectively manage large maintenance jobs such as power plant outages, refinery refits, etc. With this understanding will be the increased ability to plan for and manage such projects.

Agenda Day 3

Inputs into the Shutdown

  • Basics of Shutdowns, Turnarounds, and Outages
  • Shutdown Communications
  • Shutdown Phases
  • How to justify the shutdown
  • Timelines and audits
  • The Shutdown Organization

Planning Section

  • Scope of Work: How to Find and Pick the Jobs
  • Work Validation and preparation for planning
  • Risk Management
  • Environment, Health and Safety

Project Management Techniques

  • History of Project Management
  • Key concepts for all PM techniques
  • Critical Path Method (CPM)
  • Resources

Shutdown essentials

  • Master Schedule for Phase 2 Planning
  • Contractors: How to integrate external organizations
  • Accounting, Costs and budgets
  • Logistics: Organization for the parts, materials and supplies
  • Execution: How to manage in the face of reality.

Master Schedule for Phase 3 Execution



Master Schedule for Phase 4
Completion and Phase 5 Close out

• Metrics and Benchmarking Planning and Scheduling includes both direct and indirect measures of maintenance effectiveness.