The objective of
this presentation is to illustrate how a planned, preventive
approach to maintenance management utilizing manufacturing tools
and techniques can be a catalyst for continuous improvement. Tools
and techniques like long and short range equipment maintenance
scheduling, efficient work order management, MRO materials
planning, effective manpower utilization and comprehensive cost
management used within the framework of an integrated information
system can help achieve this. These tools provide the means for
making informed decisions, containing costs and making better use of
resources. In this presentation, we will discuss the elements of an
effective maintenance strategy and describe the tools and techniques
to achieve that strategy.
Causes and Effects
of Poor Performance
requirements for world class manufacturing systems have heightened
the need for an effective, proactive maintenance strategy.
Competitively positioned manufacturing companies emphasize striving
toward continuous improvement. Maintenance organizations are one
area where significant improvement can be realized by focusing on
the causes of poor performance and eliminating them.
We must recognize
that there is a cause and effect relationship between poor
performance and the costs of that performance. Excessive maintenance
and repair (MRO) inventories caused by inadequate maintenance
material requirements planning result in lack of responsiveness to
job requirements and large numbers of incomplete jobs. Inefficient
craft utilization and maintenance worker idle time is caused by poor
manpower planning and underutilization of labor. Loss of production
capacity because of repeated equipment failures is caused by the
lack of preventive and predictive maintenance scheduling of regular
overhauls, inspections and lubrication cycles. The effects of these
conditions are large investments of working capital for
"just-in-case" inventories, excessive overtime expenditures, high
production outages and maintenance costs which consistently far
exceed annual budget estimates and maintenance plans.
The chief driver toward continuous improvement in the maintenance
organization is through the development of a strategy for
prevention. It is a strategy that emphasizes planning and scheduling
maintenance activities to maintain equipment reliability.
A Strategy for
The foundation for
a maintenance strategy that emphasizes planning and prevention is
provided by a sound management approach comprised of these elements:
• striking a
balance between machine availability and the cost of providing
availability. The thrust is on maintaining equipment at a standard
level of perfor-
mance which will increase equipment life and minimize capital
investment and overall maintenance costs.
• delivering quality maintenance service at a required level within
an acceptable time frame to the customer—manufacturing.
• using a reliable, formalized process of planning and scheduling
the maintenance workload, monitoring performance and improvement.
Planning and executing of maintenance considers quality, quantity,
costs, timing and safety.
• preventing failures that compromise equipment availability and
reliability. Failure prevention is accomplished through the proper
mix of preventive, predictive and repair maintenance.
• reducing maintenance (MRO) inventories through better materials
requirements planning, use of equipment BOMs, time-phased ordering,
eliminating obsolete parts and coordinating material requirements
with maintenance schedules.
• increasing labor utilization ratios by efficiently allocating
resources to schedules, matching maintenance job requirements to
crew availability and using predefined job or task lists as the
basis for better planning.
With the elements
of the strategy and approach as a driver, effectively utilizing
specific manufacturing tools and techniques adapted to maintenance
is the next step toward better management of maintenance resources
and costs. These tools and techniques include:
• demand management
• workload planning and scheduling
• MRO inventory management
• manpower planning
• maintenance cost accounting
• an integrated information system
To Be Continued