Maintenance Planning and Scheduling Handbook

Streamline Your Organization for a Lean Environment

By: Randy Heisler, Ricky Smith

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Hardcover | 27 March 2006

At a Glance

Hardcover
352 Pages

Dimensions(cm)
22.9 x 15.2 x 1.91

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This is a hands-on reference guide for the maintenance or reliability engineer and plant manager. As the third volume in the "Life Cycle Engineering series, this book takes the guiding principles of Lean Manufacturing and Maintenance and applies these concepts to everyday planning and scheduling tasks allowing engineers to keep their equipment running smoothly, while decreasing downtime. The authors offer invaluable advice on the effective use of work orders and schedules and how they fit into the overall maintenance plan.

There are not many books out there on planning and scheduling, that go beyond the theory and show the engineer, in a hands-on way, how to use planning and scheduling techniques to improve performance, cut costs, and extend the life of their plant machinery.

* The only book that takes a direct look at streamlining planning and scheduling for a Lean Manufacturing Environment
* This book shows the engineer how to create and stick to effective schedules
* Gives examples and templates in the back of the book for use in day-to-day scheduling and calculations

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You Can Find This Book In

Non-Fiction Engineering & Technology Technology in General Engineering in General Science Biology, Life Sciences Zoology & Animal Sciences Business & Management Management & Management Techniques Industrial Chemistry & Manufacturing Technologies Industrial Chemistry Heavy Chemicals

Economics

List of Figures	p. xi
List of Tables	p. xv
Acknowledgement	p. xvii
Historical View of Maintenance	p. 1
Pure Reactive	p. 3
Limited Proactive Applications	p. 5
Birth of Real Maintenance	p. 6
Military Takes the Lead in Maintenance	p. 10
Long Journey to Lean Thinking	p. 12
Lean Spills Over to Maintenance	p. 15
Maintenance Operation Refinements	p. 16
The Plant/Facility Lean Environment	p. 19
Lean Origins and Definitions	p. 19
Lean Organization: Elements and Practices	p. 22
Current State	p. 25
Future State	p. 26
Lean Maintenance Operations	p. 28
Fundamentals of Total Productive Maintenance	p. 29
Work Execution	p. 33
Planning and Scheduling	p. 34
Reliability Engineering	p. 34
Lean Refinements	p. 35
Reliability Excellence	p. 35
Teams and Teamwork	p. 36
New Roles for Managers and Supervisors	p. 38
Organizational Focus	p. 38
Expanded Education and Training	p. 39
Maintenance Optimization	p. 39
Lean Maintenance: Prerequisite of the Lean Plan/Facility	p. 41
Governing Principles and Concepts of Lean Maintenance	p. 42
Lean Maintenance Governing Principles and Concepts	p. 43
Vision and Mission	p. 45
Strategic Plans, Goals and Targets	p. 46
Operations and Maintenance	p. 48
Operations Maintenance-A Partnership with Two-Way Responsibilities	p. 48
A Lean Mandated Marriage	p. 51
Why Plan?	p. 58
Advantages of Maintenance Planning	p. 58
Objectives and Goals of Maintenance Planning	p. 61
Origins of the Maintenance Planner	p. 63
In the Beginning	p. 63
Developing Standard Practices	p. 65
Basic Process	p. 65
Manufacturing's Influence	p. 70
Accommodating a Varying Workload	p. 71
Resources, Resources, Resources	p. 74
Appearance of Balance	p. 75
Organization Alternatives	p. 78
Styles for Organizing Maintenance Operations	p. 80
Style Variations	p. 81
Trade Organization	p. 81
Area Organization	p. 83
Production Department Maintenance	p. 84
Joint Trade and Area Organization	p. 87
Contract Maintenance - Partial or Total	p. 88
Organization by Work Type	p. 90
Combination Styled Organization	p. 92
Total Productive Maintenance	p. 95
Reliability-Centered Maintenance	p. 98
Incorporating Work Planning	p. 104
Planning and Scheduling: Defining the Role	p. 108
TPM-RCM-Lean Organizational Considerations and Choices	p. 109
Where Does the Planner Fit?	p. 111
Erroneous Thinking	p. 113
The Reality	p. 113
The Assigned Tradesperson	p. 114
The Responsible Supervisor (or Team Leader)?	p. 114
Fostering a Sense of Accomplishment	p. 116
Performing the Planning Function	p. 118
Principles of Planning	p. 119
Managing the Backlog	p. 120
Criticality and Prioritization	p. 122
The Work Order	p. 130
Work Order Types and Formats	p. 130
Work Order System and Work Flow	p. 133
Coding Work Order Information	p. 136
Sequence of Planning	p. 150
Job Plan Level of Detail	p. 151
The Work/Job Package	p. 154
Estimating and Work Measurement	p. 161
Planning Aids	p. 167
The Role of CMMS in Maintenance Planning	p. 169
Feedback	p. 171
Building a History	p. 178
Closing Out Work Orders	p. 181
Data Entry and Validation	p. 182
Reliability Engineering	p. 183
Lean Maintenance Planning	p. 187
Performing the Maintenance Scheduling Function	p. 189
Scheduling	p. 189
Organizational Considerations	p. 190
Scheduling Defined	p. 193
Prerequisites for Effective Scheduling	p. 195
Preparing Schedules	p. 196
Scheduling Practices	p. 197
Scope of Maintenance Scheduling	p. 199
Metrics-Schedule Compliance and Labor Effectiveness	p. 205
General Scheduling Considerations	p. 209
Special Case: Maintenance Planning and Scheduling for Maintenance Outages - The Plant Shutdown	p. 211
Planned Outages Defined	p. 213
Phase I: Definition	p. 213
Phase II: Planning	p. 216
Purchasing: Plant Shutdown Logistics	p. 219
Phase III: Scheduling	p. 220
Phase IV: Execution	p. 222
Phase V: Debrief and Lessons Learned	p. 223
Critical Path Method Scheduling	p. 224
Tips, Tricks and Avoiding Pitfalls	p. 230
Straight from the Horse's...	p. 230
Gaining Trust	p. 230
Maintenance Planner	p. 230
Maintenance Scheduler	p. 232
Attitudes, Practices and Methodologies for Success	p. 233
Empowerment and Areas of Responsibility	p. 233
Skill Levels and Training	p. 235
Tips and Tricks of Successful Planners and Schedulers	p. 237
Maintenance Planner	p. 237
Maintenance Scheduler	p. 239
Metrics: Measuring Planning and Scheduling Performance	p. 241
Planning and Scheduling Performance Indicators	p. 242
Labor Performance	p. 242
Job Planning and Scheduling	p. 243
Reliability Excellence (Rx) and the P/S Function	p. 244
Summary: Characteristics of Reliability Excellence	p. 246
Planning and Scheduling Fundamentals - Self-Test	p. 249
Approach	p. 249
Self-Test Question and Answer Section	p. 250
Self-Test Work Exercise Section	p. 253
Job/Position Descriptions	p. 255
Benchmarking and Best Practices	p. 261
Forms, Worksheets and Checklists	p. 266
Tutorials in Brief: Control Charts and CPM Schedules	p. 282
Chapter 11 Self-test: Answers and Solutions	p. 294
Glossary	p. 298
Index	p. 325
Table of Contents provided by Ingram. All Rights Reserved.

Maintenance Planning and Scheduling Handbook

Streamline Your Organization for a Lean Environment

At a Glance

Hardcover

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