Last week, I talked about how different sources of waste are impacting your maintenance performance and your plant’s reliability.
This week, let’s get into more detail on how waste is reducing the efficiency of your day-to-day maintenance execution. When you take a look at the Weekly Schedule of your maintenance crew, it will be full of productive work …
… but when you look at what an actual day for your crew looks like, you’ll see plenty of unproductive work. You’ll see plenty of time spent on
… looking for parts
… waiting on permits
… waiting on instructions
… waiting on other trades
… waiting on Operations to isolate the equipment
In short, the days of your maintenance crews are full of delays. Delays during jobs. And delays between jobs.
You can eliminate many of these delays by implementing a proper Planning & Scheduling process – increasing your wrench time from a typical 30% to 45%
Which is the equivalent of increasing your workforce by 35% – without hiring anyone! There are many versions of this process out there… but, in essence, they all come down to the same basic steps.
Here is an overview:
Step 1 – Identify & Prioritise
Step 2 – Plan
- list of spare parts and consumables
- list of special tools or equipment
- access or lifting requirements.
Step 3 – Schedule
Step 4 – Execute
- allocating work
- executing work
- managing emerging work
- reporting daily progress
- and reinstating equipment
If there are missing parts, emergency maintenance, or changes in methodologies during this step …
… then it is the Maintenance Supervisor’s responsibility to adapt to the changes.
It is important to give the planner feedback on what went well and what went wrong so that they can improve the job plans for next time. Continuous improvement is key to your success!
Step 5 – Close out
After the crew has finished doing the work, the next step is reporting the technical history, work history, and areas for improvement. This is one of the most important steps in the process. Without it, there is no improvement. Unfortunately, it is also one of the steps that many ignore.
As part of this step, the Supervisor:
- Confirms all work is complete and meets the required quality standards;
- Reviews and approves the technical history in the CMMS;
- Makes sure the Planner receives feedback on the quality of the job plan;
- Initiates a Root Cause Analysis if required;
- Ensures unused materials are back in the warehouse;
- Initiates payments.
Step 6 – Review and Improve
Again, everything that I mentioned so far is just a summary.
If you want to learn more, you can read the rest of the article or check out our online course on Maintenance Planning & Scheduling.