How to Manage Maintenance. Second Edition

Transcription

1 How to Manage Maintenance Second Edition

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3 How to Manage Maintenance Second Edition Edward Hartmann Donald J. Knapp Joseph J. Johnstone Kenneth G. Ward

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5 Contents About This Course How to Take This Course 1 Organization Structure Organization Charts and Reporting Levels Very Small and Small Organizations Medium Organization Large Organization Managerial Objectives Resources to Manage Human Resources Financial Resources Physical Resources Information Resources Maintenance Costs Maintenance Department Objectives Maintenance Department Functions The Maintenance Manager The Maintenance Supervisor Staffing the Maintenance Function Personnel Ratios Use of Primary Skills Area Organization Rules and Regulations of the Organization xi xiii 1

6 2 The Maintenance Budget 2 3 The Chart of Accounts The Expense Budget The Operating Expense Statement The Value of the Expense Budget The Capital Budget Overstaffing Deferred Maintenance Assigning Accountability for the Budget Preparation of the Budget 3 Systems for Control The Work Order Cost Information Source of Communication The Service Order Small Jobs Emergency Service Orders Open Work Orders Work Order Procedure Flow Work Order System Advantages Priority Systems The 1,2,3,4 System The Alpha Numeric System Reporting Systems Record Keeping Systems Computer Versus Manual Systems 37 4 Inventory: Parts and Materials 57 The Maintenance Inventory Ordering and Inventory Costs The Economic Order Quantity (EOQ Need Versus Cost The Role of Purchasing Maintaining the Stock Stores Catalog Technical Database

7 Control of Inventory Level Free Use Items Storage Location Pre-kiting of Parts Inventory Accuracy Lubrication Materials Measuring Stores Effectiveness 5 Maintenance Support Programs 73 History of Preventive Maintenance (PM) Categories of Maintenance Support Programs (MSP) Reliability Improvement Programs Planned Maintenance Programs Unplanned Maintenance Programs The Cost of Maintenance Support Programs (MSP) Measuring the Risk of Maintenance Support Programs Equipment Inspection Equipment Identification Inspection Procedures Inspection Frequency PM Work Order Scheduling and Routing Scheduling PM Routing PM The Manager's Role MSP Reports Uptime Report Compliance Report Ten-Most-Critical Report Work-Generated Report Graphical Data 6 Planning and Scheduling 93 The Key Elements of Planning and Scheduling Identification of Jobs to Be Planned Authorizing Work Orders Assigning Priorities The Planning Process Estimating Labor Hours Providing Information: Sketches, Prints, and Special Tools

8 Parts and Materials Needed Planning Sheet for Larger Jobs Ordering Materials Scheduling Work Scheduling Small Jobs Scheduling Large Jobs Execution of Work Review of Work Measuring Effectiveness Records Upkeep Selecting the Planner and Scheduler The Planner The Scheduler 7 Craft Training 109 Training Needs Analysis Documenting Training Needs Skills Analysis Job-related Training Functional Training Hands-on Training Instructors Upgrade Training Training Materials Existing Programs 8 Measuring Effectiveness 123 Safety Measurements Budget Variance Maintenance Cost per Unit Maintenance Cost as a Percentage of Capital Investment Additional Measures Percent of Uptime Workload Backlog Overtime Ratio Emergency Work Ratio Labor Versus Material Ratio Work Measurement

9 Estimated Time Versus Actual Time Work Sampling 9 Computerized Maintenance Management Systems (CIVIMS) What Should CMMS Do? How Do CMMS Work? Basic System Features System Modules Functions Included in Modules System Operating Details CMMS Implementation User Training Evaluation of the Facility Data Entry System Operation Reports Report Samples Benefits of Using CMMS Identifying Benefits and Savings Bibliography Post Test Case Study Case Study Solution - Selected Readings Index

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