Archive for the ‘ Planning and Scheduling ’ Category

Give Me 30 Minutes – the Weekly Scheduling Meeting

When it comes to the weekly Maintenance Scheduling meeting, I generally see two separate spectrums.  The first is no meeting or no attendees, and ultimately, no real schedule.  On the opposite end, I see the long drawn out review of the entire backlog, most of which we don’t have materials for or resources to do in the current week. That might be OK if you have very little backlog.  Most don’t.  I believe you would agree that we spend way too much time in meetings reviewing the same items week after week.

For effective scheduling meetings there are three primary components which are process, partnerships, and discipline.  From a process perspective, the Planner Schedulers working together in advance to draft the schedule, email it early in the week to the other partners, and coordinate priorities prior to the weekly scheduling meeting.  To be effective, there must be a partnership among the stakeholders to provide timely responses to changes to the draft before the meeting. The Planner Schedulers should run the scheduling meeting and use an agenda to keep everyone focused.  The discipline comes in sticking to the process and everyone enforcing the mutual partnership.

From a timing perspective, I believe you can strive for the first 15 minutes of the meeting being utilized to confirm the prioritized work schedule for next week. There should only be one schedule, not one for each craft. Follow that with 15 minutes to share last week’s metrics and to discuss any schedule breaks. Work to limit the weekly scheduling meeting to 30 minutes in total.

Is this an achievable goal in your organization?  What do you see as barriers?

Cheers,

Jeff

Busting out of our Silo

Maintenance Planning and SchedulingFrom a maintenance perspective, are you scheduling Operations and other support functions?
In many organizations, I find that people are not utilizing the CMMS/EAM to the fullest extent with respect to “crafts” when it comes to coordinating work. You will probably tell me, “Jeff, no surprise there”. It doesn’t have to be this way.

Let me explain what I mean. When I look at schedules for maintenance work, rarely do I see crafts listed other than those from the maintenance organization. Let’s take a job like welding on a product tank in a food plant as an example. We need Operations personnel to empty and clean the tank in advance of the welding work. Once the welding work is complete, we may need Operations to clean and sanitize the vessel. Following on, Quality Services or lab personnel may be required to swap the tank for microbial contamination and release it for refill with product. These are all coordination activities that we want to cover with child work orders as an example. In addition, should we not coordinate these activities from a scheduling perspective?

The bottom line is that just like we have crafts such as pipefitter, mechanic, or electrician, we should also have operator, lab tech, or other support functions identified in the CMMS. The work of those individuals and the required coordination of those activities should appear on the weekly schedule with the work order numbers/ work descriptions. When we are in next week’s scheduling meeting, we can set the expectation with Operations and our other partners that we will be needing assistance with equipment availability, possibly help with the maintenance tasks themselves, and the restart of that equipment. Approaching our maintenance tasks and their coordination from a more holistic inclusive viewpoint helps us build better partnerships with the other stakeholders.

Check your schedule and your approach. Are you doing this?

Speak soon,
Jeff

Video on the Goals of Maintenance Planning

From the People and Processes Youtube channel, I have embedded this video on Maintenance Planning

 

20 Thoughts on Maintenance Planner Scheduler Tasks

The Maintenance Planning and Scheduling function has four basic objectives:

  • To provide the right information for the technician to more easily to perform the job
  • Have identified the right parts and materials, having them staged and kitted
  • Interface with the Operations partner to ensure the equipment is available for Maintenance at the specified time
  • To ensure the right priority Maintenance work is accomplished based on business needs

In the end, the function is all about doing the right work while addressing avoidable delays i.e. driving technician wrench time up.  To do this, there are a number of tasks that the Planner Scheduler performs.

  • Avoids getting involved with this week’s emergency work as planning must be focused on the future
  • Reviews work orders requiring planning to understand the requested work
  • Evaluates and understands planned work priorities
  • Job scoping/ research – spends 1/3 of the day in the field
  • Prepares job plans based on level of detail required
  • Maintains a job plan library for reuse
  • Identifies and requisitions/ reserves parts and materials
  • Prepares the job package
  • Interfaces with the Operations group to validate work priority and equipment availability
  • Collaborates with Maintenance Supervisors on next week’s available labor hours to build the weekly schedule from
  • Develops the next week’s maintenance schedule based on priority
  • Provides a level of coordination in the planning and scheduling phases, not during the execution of the work which the responsibility of maintenance supervision
  • Leads the weekly maintenance scheduling meeting
  • Ensures the preventive maintenance program is scheduled and work-leveled
  • Maintains the asset hierarchy if so required
  • Develops and improving the asset bill of materials
  • Reports on the Key performance indicators (KPI) if required
  • Performs other administration tasks of the CMMS/ EAM if required
  • Reviews completed job feedback to improve job plan content and estimates
  •  Integrates key words on work order closure to assist the data mining for reliability engineering purposes

Are these tasks what you expect for the Maintenance Planner Scheduler?  Would you take any away and why? What others would you add and why?

Cheers,

Jeff Shiver

A Plague Lurks Just Around the Corner

Maintenance Planning and SchedulingI was recently conducting a Maintenance Planning and Scheduling course onsite.  As with all of the classes that I facilitate, I make an effort to learn about those in attendance on a more personal level.  This class was no different and shortly, I learned about the work history of several people.  One had been there for 44 years, another for 37, and a third for 31 years. The guy who had been there for 44 years was 70 years old and because of his in-depth knowledge, they were asking him to stay around a few more years.  It’s not out of financial need that he stays but a sense of duty and loyalty.

In Maintenance Planning and Scheduling courses, we always talk about the Job Plan and its use in developing precision maintenance procedures.  In the case of these veterans, the Job Plan also serves as a tool to capture their knowledge for use as a training tool later.  All too often, I see this concept ignored.  With many of the organizations that I visit, I often find the average age of the workforce at 57 years and beyond.  Without tools like the Job Plan, how can we expect to capture that knowledge prior to those individuals leaving?  How will you train those who will be needed to fill the veterans shoes?  How many of you are using the Job Plan to capture that knowledge?

Cheers, Jeff Shiver

P.S. Want to learn more about Maintenance Planning and Scheduling?  Here are some upcoming public courses that I will be facilitating in Atlanta and Chicago.

The Maintenance Job Plan Outline

If you are like many Maintenance Planners that I have the opportunity to interface with, most aren’t doing much using the job plan concept.  The intent of the job plan is to better enable the craftspeople to execute their job with the materials, tools, and information in hand.  Ideally, you really want a template to facilitate the development of these job plans.  Recently, I did a webinar for Emaint which is a CMMS vendor on creating job plans.  You can view it here. What should some of the headers be for a job plan template? Here’s an outline that you may want to start with.

  • Asset number
  • Asset name
  • Crafts required
  • Estimated hours per craft
  • Total job duration (to be able to tell our Operations partners how long we need the equipment)
  • Safety considerations
  • Tasks and sequence
  • Materials and Parts (Stock or purchased)
  • Consumables (i.e. shop towels, penetrating lubricant spray)
  • Tools and equipment (i.e. 2” impact socket, grease gun, 40’ man-lift)
  • Housekeeping and/ or disposal
  • Revision history

Most of these outline items can be used regardless of whether it’s a PM or Corrective Action job plan. Is there anything else you would add?

Cheers, Jeff Shiver

Does the Good Doctor fly Blind?

Maintenance Planning and SchedulingWhy should we bother with this job plan thing anyway, after all the Technicians know what to do, right? If you were undergoing surgery, in addition to the proper training; you would expect a surgical team to have a set of procedures and checklists to perform their work on you. What if they started operating out of sequence before you were fully sedated? What if they left some of their tools or sponges behind when they closed you up? I hear you saying “But Jeff, we aren’t dealing with life or death when we work on equipment!” When you consider the environmental and safety consequences of the equipment that we work on, that may not be the case. I would guess that many of the people involved with some of the life ending and environmental disasters in recent memory never expected things to end the way they did either.

The bottom line is that the job plan can help bring precision to our maintenance work with specifications like tolerances, gaps, fits, torque and so on.. They serve to provide checklists and sequential steps. The plans can be used as training tools when we capture the knowledge before people retire which is a ever more frequent occurrence. The effective job plan can save the technicians from spending hours searching for information or materials. It can also prevent accidents by providing concise lock out and tag out information along with the necessary PPE and required permits. One of the best parts to job plans is that they are reusable as much of our work is repeatable.

What other reasons do you have for creating and maintaining job plans? Are you successful with them? If not, why not?

Cheers,
Jeff

Get Out from Behind the Desk

The Maintenance Planner is charged with the creation and maintenance of the job plan to help drive the efficiency of the craftspeople. Since the ideal Maintenance Planner is one of your best craftspeople, they should be quite knowledgeable with regards to the steps required to complete a maintenance job.  However, there is an old saying that “the shortest pencil is better than the longest memory” for good reason, especially if you listen to how my wife reflects on how short my memory really is.  I think it’s more of a case of selective hearing but I’m not going to tell her that.

Anyway… I was recently working with a group of Maintenance Planners and they shared some maintenance tasks lists with me.  When I reviewed the procedures, I thought there might be some gaps in the tasks and their sequence. I like to adhere to the “show me” approach so I suggested that we actually walk down one of the jobs.  When we started the walk down, the Planner showed vast knowledge on the job.  The only problem was about 75% of the activities weren’t on the job plan.  He would mention a task and I would comment back “Oops, that’s not on the plan”. He would go to another task and ask “Is that on the plan?”. My reply often was “Nope”.

When we got back to their desks, the Planners told me how eye-opening that exercise was.  It turns out that a number of the Job Plans had been done from the desk using their memory.  It’s much better to walk the job and jot down the steps so that you don’t miss things from memory.

When you walk the job, you should consider the following items in addition to the normal job plan items:

-          Routing of the task steps, especially if they are located on multiple levels or require the closing/ opening of valves in a sequential pattern as examples.

-          Special tools required, even items like a rope and bucket to pull up tools to the top of the structure if using a ladders

-          Task sequence

-          OEM cut sheets and other information required to properly set up or calibrate items.

What other items should you add?

Cheers, Jeff Shiver

Maintenance Planning and Scheduling Survey, Take it Now!

Maintenance PlannerHow is your Maintenance Planning and Scheduling organization aligned? What about the Planner/ Scheduler(s) compensation? Are the Planner(s) focused on the future?

I was recently teaching a Maintenance Planning and Scheduling course when I addressed some of these questions for the class. As an outcome, I wanted to put some of the questions to the audience and get your input. To that end, I have created a survey. Once the results are in, I will provide a more comprehensive article on the outcome. It’s a short 13 questions and should take less than 3 to 4 minutes of your time to complete. Please take a few minutes and complete the survey which can be found here at http://bit.ly/dXPxl7 Thank you in advance for helping to foster the discussions in the Maintenance community.

Cheers, Jeff

Maintenance Technicians or Maintenance Planners?

Do you believe that a Maintenance Technician should perform job planning for some of their work or is that solely the role of the Maintenance Planner?  If you find for the Technician, should a Work Order be written by the Maintenance Planner to account for the Technician’s time?

This is a question that came up in a recent 4 part Maintenance and Reliability for Managers course I was facilitating just last week.  A primary goal of Maintenance Planning and Scheduling is to drive the efficiency of the crafts by preparing job plans that contain the crafts required, estimated hours, materials, tasks and sequence, and so on.  If the crafts are preparing their own plans, then why do we need the Planner you might ask?

I think that there is middle ground in this discussion. Yes, we want the Planner developing job plans and other Maintenance Planning functions.  I’ll add that we want the Maintenance Planner focused on the future (next week and beyond).  However, the Maintenance Planner can’t be everything to everyone and aren’t experts in all the jobs they may be asked to plan.  Ideally, the Maintenance Planner should develop the majority of the job plans.  If they don’t know, I believe it’s good to get input from the Technicians and Supervisors on the job plans.  I hesitate to use the term “last resort” but for more complex jobs where the Maintenance Planner has no idea; I like to see a work order written to the Maintenance Technician to develop the job plan content, especially from a materials required perspective.  This allows the Technician to be scheduled for the plan development activity and gives them a work order to account for their time.  The job plan doesn’t have to be perfect as it should contain the information needed to improve the craft efficiency (materials, crafts, and hours as a minimum).  Remember the job plan process has a continuous improvement loop where the Technician can document more detail as the job execution occurs which allows the Planner to update the content on the Work Order closure process.  What are your thoughts?

Speak soon, Jeff