LEAN MAINTENANCE
Master-class on
LEAN MAINTENANCE PLANNING & SCHEDULING
“Maintenance is not only part of the production process it must be planned into the production process.
“In short, maintenance must be integrated into the business!”
11th, 12th & 13rd June 2018| Birchwood Hotel, Boksburg, Johannesburg , South Africa
WHAT WILL YOU LEARN:
The objectives of this course include an understanding of:
ü History; present and future of maintenance.
ü What is lean maintenance – video and group work.
ü The 12 types of maintenance as developed by the facilitator.
ü The Purpose and Role of Maintenance Planning and Scheduling; including practical’s.
ü Planning and Maintenance Key Performance Indicators (KPI)
ü Maintenance Effectiveness Indicators (MTBF; FR; MTTR etc.)
ü The Maintenance Planning Work Process.
ü Standardizing Planning and Scheduling Procedures.
ü Equipment Refurbishment Decisions and Costs.
ü Elements of Sound Scheduling.
ü Staging Parts and Tools; What, Where and Who to stage, the process of staging; group work and exchanging ideas.
ü Work Scheduling & Job Sequencing group discussions.
ü Manpower Scheduling and Resources Scheduling.
ü Measurement of Maintenance effectiveness with Metrics.
ü The People Side of Planning; 12 Motivation tips.
ü Specific Planning Advice to go along with a CMMS database.
ü Effective Shutdown Execution; examples out of industry.
The Overall Objectives of this course includes:
· Minimizing the idle time (tool time) of maintenance workers.
· Maximizing the efficient use of work time, material, and equipment; out with the old and in with the new.
· Maintaining the operating equipment at a responsive level to the need of production in terms of delivery schedule and quality. Aid production to achieve TAKT and Cycle times.
· Determine the correct load on machines and equipment – eliminate overload or under load. This leads to a correct make or buy decision on the strategic management level.
Ø Use maintenance as an effective method of cost reduction and improving uptime. Maintenance saves money.
Ø Make the entire facility more efficient in all areas.
· Practical exercises of the different tools to help delegates find the methods that are the easiest for them or those that work. Best under certain conditions (Project Management Tools)
Excel Templates – Various
ü Gantt; Critical Path; PERT; Budget; Fault Reports; RCA etc.
ü The ratio of theory to practical is: 10% theory; 90% practical; including working on soft copies
ü Case Studies will be provided and worked through with delegates in a separate workbook supplied
Seats Are Limited. Book Yours Now!!!
THE WORKSHOP
Effective & Reliable (Lean) Maintenance is no longer optional to be competitive in the fast pace global business world. Lean planning and scheduling contribute significantly to the following:
· Reduced maintenance cost. Avoiding over insurance on outdated equipment/assets.
· Improved utilization by reducing the effects of the 3 demons; defects; delays and deviations.
· Waste elimination and cost reductions due to “uptime” (first time right).
· Improved people and motivation leading to internal & external customer satisfaction.
· Improved management & leadership; resulting in greater team effectiveness.
· Improved quality of maintenance work regarding man; machine; methods & materials.
· Inventory reduction and production improvement in TAKT time; Cycle time; and Standard time.
This uniquely developed course focuses on waste elimination; equipment reliability; FMEA; Planning; Scheduling and Shutdown Management. Our comprehensive soft copy templates is Excel; Six Sigma & Kaizen based and introduces you to best practice maintenance planning and scheduling systems. Delegates may bring their laptops; upload over 20 templates, work on them in groups; and leave the training empowered to go and implement in their workplace. This computerised course requires Windows 2003 – 8 and only basic knowledge of Excel; WORD and Power Point. All templates are provided on a CD. They are simplified and easy to use during and after by the delegates. PLEASE BRING YOUR LAPTOP.
Workshop Programme
Day 1
MAINTENANCE; FAILURE; RELIABILITY; ASSET MANAGEMENT:
Maintenance A – Z:
· What is maintenance? History; Present; Future.
· What Planning mainly is and what it is not.
· The author has developed solutions to the 12 most critical wastes using a combination of the Toyota Production System; Six Sigma and Lean. All done on practical Excel worksheets.
· Quality and Productivity; Effectiveness and Efficiency; the author has developed easy to use statistical process control tools (Excel).
· Desired Level of Effectiveness including the OEE; MTTR; MTBF; FR calculations.
· Weibull lifespan and failure prediction.
Maintenance Objectives and Methodologies
· The purpose and objectives of Maintenance explained in relation to the entire business.
· The Purpose and Role of Maintenance Planning and Scheduling; considering factors such as capacity; utilization & Overall Equipment Effectiveness.
o Failure Mode Effect Analysis (FMEA).
o Reliability A – Z and easy calculations.
o Downtime analysis examples.
o Standardization of all maintenance work.
Day 2
MAINTENANCE PLANNING:
Maintenance Planning and Measurements:
· What is maintenance planning?
· Maintenance Performance Prediction Indicators
· Equipment Performance Indicators.
· Planning Indicators – who; when; what; how, why, with 8D and IS-IS NOT Excel template
The Work Planning Process
· Work Order System; Scoping a Job
· PDCA Excel exercises: Prepare the resources
· Engineering Assistance or Reassignment
· Work Order Form; Coding Work Orders
· Estimating Work Hours and Job Duration
· Purchasing, Storeroom, reserving, and staging
· Special tools; jigs and innovations.
Day 3
SCHEDULING
Principles of Scheduling
· Skills required for Scheduling
· Site Investigation & Failure History
· The critical path (CPM)
· Bar Charts & Gantt Charts
· Resource smoothing
· Managing the Critical Path
Advance Scheduling
· Weekly Scheduling
· Forecasting work hours
· Sorting work orders
· Allocating work orders
· Formal Weekly Schedule Meeting
· Staging Parts and Tools; What, Where and
· Who to stage, the process of staging
· Key concepts in scheduling for outages & Planning work orders for outages
· Quotas, Benchmarks, and Standards Addressed
Work Scheduling
· The Scheduling Meeting
· Work Request for a Planned coverage
TRAINING METHODOLOGY: Facilitated by an experienced maintenance specialist, the seminar will be conducted as a highly interactive work session (as opposed to lectures),encouraging participants to share their own experiences and apply the course material to real-life situations. Each delegate will receive an extensive reference manual, as well as case studies, while worked out solutions will be handed out to the delegates on conclusion of group discussions. Throughout the seminar, delegates will be encouraged to identify what they can do to enhance Maintenance Performance Measurement and Management in their organizations.
THE FACILITATOR:Gert Oberholster has many years of experience in different aspects of Production, Projects, Logistics; Maintenance and Quality Management while being employed by various organisations. He specialises in productivity training and consultation. Gert has experience in the Toyota Production System (TPS); Value Stream Mapping (VSM); Lean Manufacturing; Six Sigma and other uniquely developed productivity templates while working with Volkswagen; Mercedes; BMW; Nampak; Toyota and other dynamic organisations. He holds a degree in Project Management, and supporting qualifications in Production, Quality; Logistics and HR. He is the author of many training manuals and unique tools using experience and teamwork with other professionals. He has invented specific templates regarding wastes; teamwork; motivation; communication; and continuous improvement.
WHO SHOULD ATTEND:
Delegates who represent a wide range of personnel in the organization who are involved in maintenance and maintenance management. These should include:
• Maintenance Managers
• Maintenance Supervisors
• Maintenance Planners
• Plant Engineers
• Production Engineers
• Maintenance Planners
• Key leaders from each maintenance craft
• CMMS Administrator or key users
Due to the interactive nature of this workshop seats are limited. BOOK NOW!! to avoid disappointment. All delegates will receive a Certificate of Attendance as well as comprehensive course documentation. Registration for this course is at 08:00am with the course starting at 08:30am, Lunch will be at 13:00 with the course concluding at 16:30. Please note that all timings are approximate due to interactive nature of the course.
Seats Are Limited. Book Yours Now
R 10 199.00!!
You are encouraged to circulate this email to people and / or organisations who may be interested to attend this workshop.
If you have any queries or require any assistance please do not hesitate to contact us.
Kind Regards,
Graham Simmons
Tel: +27 11 402 2018
Fax: +27 86 293 1295
Email: graham.simmons@platpeak.co.za
Website: http://www.platinumpeak.co.za
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