6.4 Backlog Management

We are in unprecedented times. Covid-19 wreaked havoc on supply chains; decreased production during times of increased demand. Labor shortages, chip shortages, long lead items turning into “maybe next year, if you’re lucky” items. The Russia Ukraine war added further stress to supply chains through sanctions, port closures, fuel shortages and much more. What once was reliable is now unreliable. So how can companies overcome an unreliable supply chain to maintain their reliability? There are several ways to mitigate unreliability; scenario planning, supplier management, and technology. There is no one size fits all and what may work for one company will not necessarily work for another. Scenario planning involves reviewing every potential situation that could occur, then working through to see how the company would be impacted. Ultimately this results in mitigation plans for each scenario. These can then be reviewed and implemented. Proper Supplier Management includes ensuring all suppliers have their scorecards reviewed on a regular basis. Their information updated and kept current. It can also include reviewing which suppliers can become substitutes for others in the event one is not able to provide the required product in time. Technology is important as it links all the information together. Algorithms can be created to let management know that certain parts are low, equipment is wearing out sooner, it also collects information on suppliers for the scorecards. Overall technology is the glue that binds and provides real time information updates. This presentation will review how to best use technology to help mitigate reliability and supply chain issues.

We’ve all heard time and time again the value that Planning and Scheduling brings to a Maintenance organization. But, is your organization fully realizing this value? If Planning and Scheduling is intended to be a “wrench time multiplier” of you Maintenance Technicians, have you looked at the “wrench time” of your Planners and Schedulers? What are the potential barriers preventing them from achieving the ultimate goals of their roles? Can one Maintenance Planner really bring the same effective value as 15-17 tradespersons in your organization? Likely not, and it isn’t the fault of your Planners and Schedulers. In this presentation we’ll review the planning and scheduling function, define what it really is, and more importantly what it is NOT. We’ll also take a close look at many of the “value vampires” common in Planning and Scheduling that detract from the intended value generation. We’ll compare what an ideal Day-in-the-life of a Maintenance Planner should be against the realities they so commonly face. The intent of this presentation is to help you understand Why Planning and Scheduling is likely less effective than it could be in your organization. More importantly, this will hopefully trigger changes that help the Planners and Schedulers in your teams do more of what they do best.

Sharing a recent mandate with a mining client where we assessed the maturity of maintenance management. The webinar will also cover the findings and our actions for improvement.Approach   1. After dozens of interviews from trades to maintenance manager, from operators to supervisors, we started to gather an understanding of the situation.   2. Then, a thorough analysis was performed on work order history, PM percentage vs total available work hours, schedule compliance and production KPIs to help pinpoint several recurring issues.   3. The analysis was concluded with on-site shadowing of supervisors and trades. We selected key dates to execute day-in-the-life-of exercises (i.e., shutdown days) to assess the quality of shutdown management and observe the execution effectiveness. Actions in partnership Tool time is a powerful metric because it helps to expose the majority of the teams’ shortcomings: engagement of the team, respect of processes, communication between departments and productivity of all the maintenance members. After the assessment and analysis, we got to work:   1. Work management process   2. Maintenance tactics review     3. Maintenance execution   4. Spare parts analysis Results With a SWAT team approach, we reduced maintenance backlog by 20%, which allowed us to focus on high criticality assets. In less than 8 weeks, we started to see a reduction in major breakdowns of equipment. We started performing root cause analysis on each breakdown and defect elimination workshops to achieve better reliability. By reducing waste related to maintenance activities in planning & execution, the team managed to transfer the work hours toward preventive tasks. The actions got translated into an improved plant availability and higher engagement

L'objectif de ce webinaire, sera un partage d'un récent mandat chez un client minier ou ils ont fait l'évaluation de la maturité de la gestion de maintenance. Le webinaire couvrira également les découvertes et nos actions pour l'améliorer.Agenda de la présentation:- Contexte opérationnel- Évaluation (analyse de données et temps d'outil)- Découvertes- Action en partenariat- Résultats préliminaires- Les actions prochaines pour fiabiliser les opérations

Written by a Certified Maintenance and Reliability Professional (CMRP) with more than three decades of experience, this resource provides proven planning and scheduling strategies that will take any maintenance organization to the next level of performance. The book resolves common industry frustration with planning and reduces the complexity of scheduling in addition to dealing with reactive maintenance. You will find coverage of estimating labor hours, setting the level of plan detail, creating practical weekly and daily schedules, kitting parts, and more, all designed to increase your workforce without hiring. Much of the text applies the timeless management principles of Dr. W. Edwards Deming and Dr. Peter F. Drucker. You will learn how you can do more proactive work when your hands are full of reactive work.  Maintenance Planning and Scheduling Handbook covers:   •The business case for the benefit of planning.   •Planning principles.   •Scheduling principles.   •Handling reactive maintenance.   •Planning a work order.   •Creating a weekly schedule.   •Daily scheduling and supervision.   •Parts and planners.   •The computer CMMS in maintenance.   •How planning works with PM, PdM, and projects.   •Controlling planning: the best KPIs KPIs for planning and overall maintenance.   •Shutdown, turnaround, overhaul, and outage management.   •Selling, organizing, analyzing, and auditing planning.           Palmers "Maintenance Planning and Scheduling Handbook" is listed a reference for Module 6 of the PEMAC  Maintenance Management Professionals (MMP) Program.

Even under normal circumstances, most of us have difficulty finding the time to do what we need to do – under these uncertain times it is exponentially harder. What can count on in one month, two months – even two days? For those organizations who are still up and running and for those hoping to come back up and hit the ground running – there are definite challenges. In this discussion we will look at these challenges and hopefully give you some hints to help decide – what can be deferred and how you can keep that to the minimum.

Coordinating all of the maintenance activities within a site can be overwhelming. A schedule is supposed to help reduce the sense of being overwhelmed. But why is it that when trying to pull together a schedule for the next shift, day or week, it always seems to be a mad dash?Having a simple, easy to use scheduling process can reduce the mad dash and enable us to project an image of being in control of our work. This leads to trust with the Operations planning team, creating an integrate schedule.

Reliability engineers in industry are often thrown into the position with very little knowledge about what they’re supposed to do. Or, sometimes, the organization isn’t set up to take advantage of what a reliability engineer can do. Sometimes these engineers have the theoretical knowledge from college but never learned what will be used in the real world. This presentation will address all the basics a new reliability engineer must know. We’ll focus on managing existing equipment and provide an overview of the reliability engineer’s role in new equipment procurement and design. We’ve found that the role of a reliability engineer is not often clear; in fact, many reliability engineers end up doing a lot of work not always related to what they should do.

Based on real-world experience this invaluable guide and reference tells the whole story of maintenance planning from beginning to end in a concise and easy-to-follow manner. Written by well-known professionals this new edition focuses specifically on the preparatory tasks that lead to effective utilization and application of maintenance resources in the interest of the reliability essential to business objectives. It comprehensively examines the job preparation process from job scoping and planning, to determination of material requirements, estimation of labor requirements and job duration, coordination of all involved parties, and job scheduling. And it includes essential metrics for measuring performance of all contributing functions. It is a vital training document for planners, an educational document for those to whom planners are responsible, and a valuable guide for those who interface with the planning and scheduling function and are dependent upon the many contributions of planning and scheduling operational excellence.This is the text book for MMP Module 6.  It is available for purchase through PEMAC, by contacting; pd@pemac.org