Work Planning & Control

Introduction

Companies achieving and demonstrating high performance have established a comprehensive asset performance management system. Work planning and control and continuous improvement make up that APM system.
This workshop introduces the importance of work planning and control and then discusses each element of the work control process from requesting to completion, reporting work execution and outstanding work.
The workshop then covers good practices in reporting including KPIs and then different data analysis techniques using data from data historians and equipment history.
Downtime reduction is not given the attention it deserves and we look at some aspects including critical path analysis. We will conduct a simple example manually and then do the same example in MS Project.
Finally, we look at root cause analysis techniques and when to conduct 5 why and a full RCA analysis.

After this Workshop you will
  • Have a greater awareness of work planning & control process
  • Understand the importance of good planning & estimating
  • Understand the principle of network analysis as applied to shutdown planning
  • Raise the quality of feedback reporting
  • Have a better understanding of what to do with the data collected
  • Produce more focused maintenance reporting
  • Have a better understanding of how to reduce downtime and repair times
  • Know when to apply 5 why or RCA
Contents

Topic 1 Common Problems in Work Management
Discussion on delegates' perceived problems
Why CMMS systems fail to deliver the results expected (simply it fails to either set-up correctly or is inadequately used)

Topic 2 Introduction to Work Planning & Control
Taking a holistic view of maintenance
Goals of work planning
What happens when we don't plan effectively?
Key planning codes
Role of the maintenance planner

Topic 3 Work identification & Requesting
What makes a good request
7 rules to follow for requesting
Examples of poor requesting
Use of priority codes

Topic 4 Work Planning & Defining the Work Scope
Goal of the Job Plan
Describing the work scope and resources
Different job plan format styles
Good practices and examples of bad practices
How much of your work is repetitive
Different types of job plans one-time, preventive, repeat repairs

Topic 5 Work Estimating Techniques
Importance of estimating
Different estimating techniques
Analogies from the car industry
Example of poor estimating

Topic 6 Work Scheduling and Execution
Discussion on scheduling
Long term, medium and short term scheduling
Scheduling meetings
Breaking the schedule with emergency work
Supervisor's role to ensure quality and safety objectives

Topic 7 Feedback Reporting
Results of poor feedback reporting
What makes a good report?
Failure reporting process

Topic 8 Completion & Work Control
Completion
Work control reports

Topic 9 Performance Reporting
What makes a good performance report?
Using different types of charts, Pareto, Z-Chart, Histograms, Cumulative Charts
Exercise: constructing charts
How to select KPIs for key result areas
Performance reporting system

Topic 10 Simple Data Analysis Techniques
Types of charts pdfs, reliability, failure rate
Data formats and types and censored and uncensored data, e.g. data from CMMS and machine historians
Weibull analysis
Exercises: analysing data set manual and with software

Topic 11 Introduction to Maintenance Decision-Making
Introduction to decision making based on costs
Exercise: comparing the costs of different strategies based on costs
Exercise: Weibull Analysis and determining the optimum maintenance strategy
Exercise: evaluating different options for a bad actor

Topic 12 Downtime Reduction
Defining maintainability
Discuss maintainability steady state metrics MTTR
Discuss maintainability based on time
Elements of downtime including wrench time
Overview of improvement techniques
Downtime reduction using the sequence of event approach. Delegates are invited to bring along a case study involving a repair where the repair time was significant

Topic 13 Critical Path Analysis - for Shutdown Reduction
Introduction to network analysis and critical path analysis
Exercise: network analysis for a simple shutdown
Exercise: using Microsoft Project to conduct the same exercise

Topic 14 When to use 5 Why & Root Cause Analysis Techniques
Introduction to root case analysis techniques
Overview of techniques including software solutions
When to use the 5 why approach
When to conduct a format RCA/RCFA

Training Methodology

PowerPoint slides. Delegates will learn by active participation during the workshop and through the use of exercises, questionnaires, case studies
Delegates are requested to install a demo version of Weibull 9 from www.reliasoft.com
A laptop is required with MS Excel, Microsoft Project and Weibull 9 (optional)

Who Should Attend

Maintenance Planners
CMMS Clerks
Reliability Engineers
Engineers responsible for maintenance of areas of the plant
Anyone who is responsible for operating or maintaining assets