Mastering Advanced Maintenance Planning and Scheduling

Introduction:

Effective maintenance practices are crucial for the growth and efficiency of business enterprises, impacting equipment capacity, product quality, safety, health, the environment, and production costs. World-class maintenance can lead to significant improvements in plant performance, enhancing customer satisfaction, employee pride, and vendor relations.

Operational success heavily relies on effective maintenance planning. For organizations aiming to achieve world-class standards, maintenance should be integrated into the overall organizational strategy rather than being treated as a standalone activity. This approach ensures that maintenance contributes to the broader goals of high-performance operations.

The maintenance strategy must align with both managerial and technical requirements, incorporating advanced technology, processes, and practices to manage new assets and minimize the operational costs of existing ones.

Objectives:

At the end of this Maintenance Planning and Scheduling course, participants will be able to:

• Understand how maintenance contributes to achieving business objectives.
• Describe the organization and execution of maintenance activities.
• Define roles, processes, and procedures relevant to maintenance management.
• Assess managerial and technical performance across organizational levels.
• Enhance machinery performance in the short term and optimize asset health for the long term.

Training Methodology:

• Case Studies
• Workshops
• Simulations
• Group Discussions
• Presentations
• Role-Playing
• Interactive Exercises
• Scenario Analysis

Course Outline:

Unit 1: Maintenance Objectives and Strategy

• Relevance of maintenance changes
• Role of maintenance in the current business environment
• Reducing unnecessary expenses and driving improvements
• Understanding downtime vs. maintenance costs
• Benefits of effective maintenance
• Evolution of maintenance management
• Maintenance classifications and scheduling
• Achieving high-level reliability maintenance

Unit 2: World-Class Standards - Comparing Your Plant With The Best

• Maintenance performance evaluation and benchmarking
• Self-evaluation of maintenance activities
• Planning, executing, reviewing, and continuous improvement
• Configuring OEE and electronic monitoring with advanced equipment

Unit 3: Implementing New Management Approaches

• RCM (Reliability-Centered Maintenance) and failure-friendly programs
• Total Productive Maintenance (TPM)
• Life-cycle costing
• Maximizing the use of CMMS (Computerized Maintenance Management Systems)
• Common issues with CMMS implementation

Unit 4: Optimizing Maintenance Organization

• Achieving operational excellence
• Integrating operations and maintenance
• Evaluating the role of maintenance within management activities
• Lessons in operations and maintenance
• Contract maintenance considerations
• Notable figures in maintenance management

Unit 5: Maintenance Planning and Control

• Overview of maintenance workflow processes
• Handling work requests and work orders
• Planning and scheduling maintenance activities
• Managing backlog and resources
• Spare parts and maintenance budget management
• Capital budgeting and asset replacement analysis
• Maintenance operating expenses
• Encouraging innovation and creativity in maintenance