Maintenance Planning

Maintenance Planning for daily abnormality findings.

This chapter will talk about maintenance planning in more practical way and simple. Most of source  I got from "Maintenance Planning and Scheduling Handbook" by Richard  D. Palmer. and by my experience as Maintenance planner for more than 5 years .

What is Maintenance planning ? and how it impact to daily maintenance jobs ?

Maintenance planning for daily abnormality is about how we can arrange our daily machine abnormality in the field, create work package, execution, and job priorities. so that it will affected to our daily maintenance performance, less backlog, cost, loss time, and man power arrangement.

in this case, daily maintenance planning should be done by Maintenance planner. for planning principle I suggest you refer to Maintenance planning and scheduling Hand book by Richard D. Palmer. Now, I will share simple way to arrange daily maintenance planning for abnormality findings in the field, followed base on what I have done when I was as a Maintenance planner.

Before  I giving an example, I will explain about 3 sub-topics that related and important when doing Maintenance planning for daily job.

1.1 Wok Priority

Work Priority is a numerical "code" that describe the urgency of the work notification/order. in SAP uses 0-4 codes from least, most urgent until during shutdown.

and the codes  area ;      0 = Immediately,             1 = Within a day,              2 = Within a week

                                       3 = Within a month,       4 = During Shutdown

                         

1.2 Equipment Criticality / Rank

In previous page I already explain about equipment criticality.

ABC indicator is assigned when creating a SAP-PM functional location record - when a Notification is created and a functional location chosen, the ABC Indicator will be carried with the Notification and Work Order.

1.3 Prime Number

This is a numerical calculation within SAP-PM to blend both work priority and location/equipment criticality – and by which backlog reports can be generated. All backlogs are sorted by PRIME.

When selecting work to be planned, scheduled, etc., the most important work to be considered should be at the top of the list.

Prime Number, combination criticality and priority will be use to sorting out most urgency of the work order,  easier when we decide which job are should be done first base on their prime number.

as a maintenance planner ( mostly daily in the morning ) I should check new job notification in CMMS - SAP system. and then make list out and review one by one for new notifications. each notification we should track out the history of the equipment ( last downtime or parts changed ).

 source ; maintenance planning and scheduling hand book - Richard D. Palmer

After explanation above,  let's take an example when arrange maintenance planning for daily job........

  

assume that we have problem with Centrifugal pumps for hot water, with specific malfunctions is the Flexible Coupling are worn out.

for above notification I will create Maintenance order and decide job criticality ( the categories are ; Immediately, Within a day, within a week, within a month, during shutdown), and for case above a decide criticality for his job is within a week. Some things that need to be considered as planner when planning the job are about spare part availability, man power availability, the job can be execute during running or not, plant need to stop or not, safety issue, and assessing for special tools ( Heavy Equipment, Hydraulic Jack, Slings, Chain Block, scaffoldings and etc. ).

during create maintenance order for job above, I will make job scoping to create work packaged as below :

• Flexible coupling spare parts
• arrange manpower  ex ; need Mechanics 2 person and Helper 1 person
• Need Slings belt and  Chain block.
• Cold Work Permit
• and wrench tools set for disassembly couplings. ( further discuss with mechanic ).

All of Items above, Is "work Package".  and I will continue create the  same work packaged with different items for another job notifications.

to be noticed that, a maintenance planner should have experience in the field, so that  during make job scoping they will understand what are to be prepared for kinds of those jobs.

and all work package that prepared send the work order print out to Mechanical Supervisor. the supervisor will decide the scheduling for the jobs base on their Prime Number, when to be execute ( the date and time )  and who will be execute ( the name of technician ).

Above is a brief explanation or best practice of applying the concept of maintenance planning for daily abnormality findings.