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How To Manage Maintenance, Second Edition

 How To Manage Maintenance, Second Edition

Authors: Edward Hartmann, Donald J. Knapp
Credit: 2.0 CEUs
Testing Format: multiple choice
Your Price: $159.00
ISBN: 9780761214205
Format: Book

Overview

Maintenance plays a key role in how productive and profitable a company can be.

How to Manage Maintenance focuses on the important role maintenance and maintenance management play in determining how productive and profitable a company can be. You’ll learn the vital aspects of maintenance—organizational structure, the maintenance budget, control systems, inventory, maintenance support programs, planning and scheduling, training, and Computerized Maintenance Management Systems (CMMS). Forty-seven charts, diagrams, tables, graphs, and forms reinforce and clarify the text.

Course Objective: Learn how maintenance management affects productivity and profitability and develop skills to effectively manage maintenance by focusing on seven critical areas.

Selected Learning Objectives

• Bring leadership and proven management techniques to the maintenance manager’s role.

• Reduce maintenance backlog, control costs, reduce maintenance inventory and stockouts.

• Increase maintenance productivity, establish preventive programs, assure the vitality of the plant’s equipment, extend equipment uptime, and improve customer satisfaction.

• Motivate the workforce, and wisely use available information resources

• Develop an appropriate maintenance budget which makes allowances for unforeseen emergencies.

• Install a Computerized Maintenance Management System to increase scheduling efficiency and productivity.

Testing Format

This course contains one multiple choice test valued at one Continuing Education Unit (CEU) and one examination case valued at one Continuing Education Unit (CEU).

Table of Contents

About This Course

How to Take This Course

1. Organization Structure 1

Introduction

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

Summary

Review Questions

2. The Maintenance Budget 23

Introduction

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

Summary

Review Questions

3. Systems for Control 37

Introduction

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

Summary

Review Questions

4. Inventory: Parts and Materials 57

Introduction

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

Control of Inventory Level

Free Use Items

Storage Location

Pre-kiting of Parts

Inventory Accuracy

Lubrication Materials

Measuring Stores Effectiveness

Summary

Review Questions

5. Maintenance Support Programs 73

Introduction

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

Summary

Review Questions

6. Planning and Scheduling 93

Introduction

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

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

Summary

Review Questions

7. Craft Training 109

Introduction

Training Needs Analysis

Documenting Training Needs

Skills Analysis

Job-related Training

Functional Training

Hands-on Training

Instructors

Upgrade Training

Training Materials

Existing Programs

Summary

Review Questions

8. Measuring Effectiveness 123

Introduction

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

Estimated Time Versus Actual Time

Work Sampling

Summary

Review Questions

9. Computerized Maintenance 137

Management Systems (CMMS)

Introduction

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

Summary

Review Questions

Bibliography

The First Examination

The Practice Case

The Practice Case Solution

The Examination Case

Selected Readings

Index