Maintenance Planning and Scheduling.

    “Success in all tasks relies on prior preparing, and failure chances are more without prior preparing.”

Maintenance Planning and Scheduling plays an important role in the company because it helps in increasing the efficiency and productivity of the plant and also focus on the vision and mission of the organization. It also provides the safe atmosphere to do the maintenance in proper sequence by reducing wastage of time. It enables a maintenance tradesperson to get ready in advance with the tools, parts, devices and equipments as suitable for the job or breakdown. By doing this one should save time when someone demands work to be done, a maintenance organizer would basically decide and collect the necessary tools sometime recently the work is allotted. The organizer might indeed write instructions on how to do the work. With this type of approach in work, the person actually attending the problem would not have to waste time in getting everything prepared. This arranging strategy would be thought to increase plant productivity along with maintenance efficiency. Overall it contributes is by minimizing the waste of time and asset so that efficiency can be increased.

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Maintenance Planning and Scheduling is a major technique to progress maintenance efficiency with respect to ineffective maintenance time.  Its function is to deliver a good plant capacity. But it could be discipline that is hard to achieve and hard to maintain specially in the large industries. It requires be supporting and creating carefully on regular intervals. If an organization wants to do anything effectively and efficiently then planning and scheduling must be a significant activity. For effectively implemented of any strategy or procedure there must be strong planning and scheduling. In addition to ensuring successful results, a well planned and scheduled maintenance approach also saves a lot of money and time. It also helps solve issues and prevent failures as we can find out what went wrong and how we will solve it as it is a step by step method. Anybody who is having knowledge of the organization’s infrastructure can enhance efficiency, effectiveness and reduce general maintenance cost over time for the organization. For this we have to do the work breakdown structure as shown:

      What to do?         ( Identify Work)

      How to do?           (Plan Work)

      When to do?         (Schedule work)

      Who will do?         (Execute work)

      Monitoring.            (Records)     

      Analysis for better results in future.

http://www.lifetime-reliability.com/tutorials/maintenance-planning-scheduling/MPS_Day2_World_Class_Maintenance_Planning.pdf

Benefits.

      Reduce store inventory and save money.

      Record of the work for future analysis.

      Improve wrench time and improve workflow.

      Improve efficiency due to effective use of working hours.

      Provide safe work place and reduce accidents and stress on shop floor.

What’s the Difference between Maintenance Planning and Scheduling?

Work Identification.

Work identification is the first step of successful maintenance management. Indentifying the work to be accomplished is a main component of the successful implementation of maintenance management. This contains the estimated information about the effort of the work and equipments to complete the task along with time and effectiveness. It also gives the idea for the upcoming issues, constraints and obstacles which may disturb the work in future.

For example, We have change the chuck jaws of lathe machines, work identification will tell us where we have to do work, on which machine, what are the descriptions of the machine, what are the safety precautions we have to take while changing jaws and estimated time along with the step by step methods involve in changing the jaws.

Planning.

“Successful Organizations are run by system not by persons.”

Planning give the information regarding objectives and procedures through which a person can achieve those objectives. The purpose of planning is to get good efficiency and effectiveness.

      What is the task?

      How will we do the task?

      What equipments we need to perform this task?

For example, we have to change the chuck jaws of lathe machines, planning will tell us that task is to change the jaws then it tell us the method to change the jaws and what will be the time required for this changing the chuck jaws.

Scheduling.

Scheduling give the information regarding the worker who is going to be responsible for the task along with particular site or location with the specific period of time. The purpose of scheduling is prevent failure by doing proper maintenance by putting least effect on production and selecting appropriate equipments and skilled persons to the task at right time.

      When the works start to do the task?

      Who will be responsible to do the task?

For example, we will replace the chuck jaws should be replaced when its length decrease by 75 % of its original length and operator is responsible for the replacement of the chuck jaws.

Work planning should be performed before a work is scheduled. The planner is going to plan the strategy, the scheduler is going to coordinate this plan with tradesperson and then tradesperson is going to do the work and this is how the work is completed.

Executing.

“The work which is not checked is not done.”

Work execution is a scheduled method of performing the planned maintenance. Once the task has been allocated, the maintenance persons are responsible for completing the task according to the planning in scheduled ways. It is hard to implement because it is tuff to measure and manage a concept.

 For effective execution of the work we have to use some tools as mentioned below :

      Reminders to let people when things are coming due.

      Triggers are action based so that if one action occurs, its triggers another action in work flow.

      Automation will be there to reduce the fatigue and stress.

      Breaking work into small portions.

      Aligning work as scheduled.

      Positive and creative environment.

      Discussing running work with experts.

Recording.

Recording and monitoring is the tool in which we collect and save all the data, methods or ways which are adopted to complete the task. Records are often depends on previous methods, techniques and strategies by which it utilize essential sources and other proof to investigate or research further. This is the written collective information which is store for years and years.

Analysing.

Analyse of the work is to study the previous history of the problem and find the more accurate and effective way to improve the methods in solving the problem. It is important in business to understand the problems and take an appropriate action to solve the problem. It also helps in decision making and operating task in easy way with more efficiency.

Let have an example to get more understanding of the Maintenance planning and scheduling.

We have to replace the set of jaw from Hydraulic chuck of Cincinnati Milacron TC -22 Shed 4 Axle turning line.

Front view of TC – 22 with closed door

Front view of TC – 22 with open door

Machine Description

Machine Make

Cincinnati Milacron

Machine Number

TC-22 Shed 4 Axle Turning Line

Model

8 C ( 1948)

Type

Computerized Numerical Controlled  Turning Lathe

Chuck Size

203.2 mm / 8 inches

Chuck Bore

76.2 mm / 3 inches

Chuck pressure

400 PSI / 28 Bar

Jaws

MT 4  Standard Soft Jaws

Swing

558.8 mm

Power

14.9 Kw

Maximum RPM

4000

Spindle Motor

20 HP

Turret Travel

1016 mm

Turret Position (tool holders)

12