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Failing to Plan Negates Maintenance Efficiency (page 3)

Planning and scheduling tools
An effective computerized maintenance management system (CMMS) is the best tool to manage multiple repairs and work orders, craftspeople, and parts inventory and, most importantly, to track and report effectiveness and results. In smaller settings without a CMMS, a spreadsheet program such as Excel could be used.

Planning and scheduling is an information-intensive job and computers must be used to manage resources, track multiple tasks, and generate reports.

Measuring the effectiveness of a planner
A key ratio to measure the effectiveness of the maintenance planning function is the ratio of planned to unplanned work. If the planning function is working at peak efficiency, reactive work should fall to a low single digit percentage. Another important measure is planned/scheduled work compliance. An effective program will be above 90 percent.

Although planning and scheduling seems simple, it requires absolute management support on a level equal to the support that safety programs receive. In other words, it must be allowed a budget and dedicated personnel who will receive ongoing skills development training. Active management support is vital to the program's success.

Benefits to an effective maintenance and planning function
"One of the biggest benefits has come from shutdown management," Juhnke says. "We had much tighter budgetary control and, for the first time, we were able to start up all five plants within two hours of our target. We also have been able to reduce our use of contractors because planning has freed up our maintenance craftspeople to perform the work themselves."

By its very nature, an effective maintenance and planning function will move away from reactive toward proactive maintenance work. The benefits to this type of environment are increased safety, worker morale, and job satisfaction.

Many planners and schedulers also serve a CMMS data quality assurance function as they close work orders as reported by maintenance craftspeople and ensure that the data is accurate and in the correct format.

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