The Optimal Management for Planning the Maintenance Activities
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The Optimal Management for Planning the Maintenance Activities
Transcript of The Optimal Management for Planning the Maintenance Activities
The Optimal Management for Planning the Maintenance Activities
Index
• Purpose and Objective.
• Available packages of CMMS packages in the market.
• Grouping of PM Work Orders; Limitations and Restrains.
• Types of available PM Grouping Methods.
• Presenting the new type of Grouping PM Work Orders .
• Smart CMMS System for Planning PM Work Orders.
• Conclusion.
Purpose & Objective of the Workshop
This workshop introduces a new strategy and a technique to:
• Enhance and improve performance,
• Reduce operational costs,
• Increase efficiency and effectiveness.
• Handle the maintenance scheduling in optimal process.
The objective of this workshop is to introduce a new process for
grouping PM work orders in order to improve work force
productivity and work quality by anticipating and eliminating
potential delays through planning and coordination of labor, and
equipment access.
Available packages of CMMS packages in the market
• Maximo System
• ERP System
• SAP System
• eFacility System
• Ramous System
• Data Stream System
• Coswin7 System
• Facility Intelligence system
• ETC,……………..
The benefits of a properly operated preventive
maintenance program:
• Equipment downtime is decreased,
• The number of major repairs are reduced.
• Better conservation of assets and increased life expectancy of
assets,
• Eliminating premature replacement of machinery and
equipment.
Why Preventive Maintenance
A Complete System For Maintenance Department
Site Name
Location
Assets
Assets can be organized based on location. Under each location,
assets can be structured into parent and child hierarchies.
Structure for CMMS’s Asset Inventory
Maintenance Planning & Scheduling
• The basic goal of planning and scheduling is avoiding delay, saving time and money.
• Concerning planned maintenance, a new type of grouping PM work orders is introduced
in order to perform PM maintenance activities with minimum manpower required,
saving time, and money as well.
• Maintenance scheduling refers to the timing of planned work, when the work should be
done and who should perform it.
• It offers details of "when" and "who."
• Scheduling is meant to schedule the maximum amount of work with the available
resources. Schedule according to the highest priority work orders.
Grouping of PM Work Orders; Limitations and Restrains
The preventive maintenance work order gives users the ability to
control, plan, schedule, and identify labor to do the work within a
specific timeframe.
Preventive Maintenance: Carried out at regular periods to
prevent breakdown or serious functional impairment of
equipment. In addition to improved performance and reliability a
reduction in costs can be obtained by the avoidance of repair
work and down time. These tasks are of an important nature and
require the skills of qualified technicians who are familiar with
the equipment to carry out the work.
Manage Groups of Work Orders
One of the main challenges that maintenance organizations in asset‐intensive companies
are facing is the grouping of different equipment that can be maintained together.
Companies can have hundreds of thousands pieces of equipment. Most of these pieces of
equipment need different preventive maintenance plan to prevent them from breaking
down. Having a systematic framework for the grouping of equipment helps develop a
preventive maintenance plan for each group instead of each piece of equipment. This will
reduce the number of preventive maintenance plans in the company and thereby reduce
the complexity of managing the preventive maintenance plans.
There are well‐developed studies about grouping execution of maintenance activities during
the scheduling phase, after the activities are planned. However, the challenge of grouping
equipment to be maintained according to the same preventive maintenance plans suffers
from lack of academic and empirical studies. Product management practices in the
companies are also suffering from the same issue.
Preventive MaintenancePM Group Definitions and Cases
Preventive MaintenancePM Group Definitions and Cases
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Types of PM Frequencies
Planning Work Orders
Maintenance Cycle Annual Loop.
Assumptions defined for PM / CM work orders scheduling process
• PM work orders have nothing to do with replacing spare parts.
• PM work orders only cover the manpower cost.
• CM work orders are only involved with repairing equipment and
replacing spare parts.
• One CM work order per equipment.
• PM grouping for CM work orders is possible for certain special
cases such as lubrication cases.
• How to add costs to a PM work order whenever the issue of
consumable costs is to be considered? How to estimate the
consumable costs to PM work orders. These costs maybe
considered as indirect or overhead costs that are needed to be
estimated.
• To manage these expenses is import to have precise maintenance
cost on each equipment.
• It is proposed to charge the cost of lubrications to one PM group
of a corrective work order.
Assumptions defined for PM / CM work orders scheduling process (Continue)
Annual Task List for the Submersible Pump
*Use CM work order if so.
Consumables
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Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files.
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files.
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files.
Step 1: Selecting the required data from the input data files. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 1: Selecting the required data from the input data files. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 2: Arrange data for PM Grouping D Type.
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 2: Arrange data for PM Grouping D Type. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 2: Arrange data for PM Grouping D Type. (Continue)
Required Steps to Obtain the Optimal Planning of PM Work Orders
Step 2: Arrange data for PM Grouping D Type. (Continue)
Now enter these data into CMMS System in order to generate the requested planned PM Work Orders.
Required Steps to Obtain the Optimal Planning of PM Work Orders
Now enter these data into CMMS System in order to generate the requested planned PM Work Orders.
Partial selection of the data for a demo purposes.
For PM Grouping D Groups (D100 – D101 – D102 – D107 – D108)
The output of the automated process of generating PM work orders that are distributed in a balanced manner.
Smart CMMS System
60 Work Orders
Analysis & Remarks
Instead of having 288 work orders, only 60 work orderswere generated to cover all PM Maintenance work for 24equipment for the whole year.
ConclusionThe outcome of this workshop concerning planned maintenance work activities issummarized as follows:
1. Issuing one PM work order for equipment “A” results in a precise cost for themaintenance cost of equipment “A”.
Total annual / monthly maintenance cost for
Equipment “A” = PM work orders + CM work orders
BUT this strategy costs time and more manpower in order to be executed and achieved.
2. Issuing one PM Group D work order for chosen equipment that have same maintenancefrequency, same forecasted man hours, and same required manpower result in a precisecost for the maintenance cost for each equipment within the chosen ones.
This strategy saves money and time.
Thanks You
