The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota, that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic "lean manufacturing". Taiichi Ohno and Eiji Toyoda, Japanese industrial engineers, developed the system between 1948 and 1975.
Originally called "just-in-time production", it builds on the approach created by the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno. The principles underlying the TPS are embodied in The Toyota Way.
The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota, that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic "lean manufacturing". Taiichi Ohno and Eiji Toyoda, Japanese industrial engineers, developed the system between 1948 and 1975.
Originally called "just-in-time production", it builds on the approach created by the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno. The principles underlying the TPS are embodied in The Toyota Way.
A presentation on TPM and its goals, pillars, and other aspects have been explored as well as its relation to 5s, OEE these tools also have been shown. In the end, step by step implementation of TPM is also discussed.
This Project presents a case study in inventory management of Mercedes Spare Parts of a service company. This project aimed to minimize the total costs of the inventory in the company through developing and optimizing various inventory management models of the company’s various spare parts.
Companies that optimize their inventory reduce inventory items and stock levels, avoid associated carrying costs and obsolescence write-downs. Want to know the best practices to optimize your inventory, check the presentation-
Frame and Body of Automobile
Introduction to chassis, Classification of chassis, Conventional chassis,
Semi forward chassis, Full forward chassis, Engine at the front, Engine at the rear, Engine in mid, Frame of the automobile, Function of Frame, types of frame, conventional frame, semi-integral frame, integral frame, defects in chassis, Body of the automobile, types of the body in automobile,
Maintenance Planning and Scheduling are key elements that influence the true success of any organization. Many times we have a planner or planner/scheduler, but do not know how to use him or her effectively or efficiently.
Design and crash analysis of a rollcage for formula sae race careSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Boost Equipment Performance, Save Money With Proactive MaintenanceJames Fitzgerald
Proactive, timely maintenance of plant equipment is critical to enabling manufacturers to meet a dizzying number of demands, from pressure to achieve target output levels, minimize labor costs, control parts spending and ensure maximum uptime. Manufacturers rely on their maintenance departments to help achieve these goals on a daily basis. However, a great number of manufacturers still use maintenance on a reactive basis rather than viewing it as strategic to operations. Myrtle Consulting helps manufacturers convert maintenance into a proactive, scheduled operation that is used strategically to control costs, maximize uptime, and maintain critical equipment. By following a few fundamental principles, plants can begin to establish a maintenance improvement program that supports operations and improves plant performance.
A presentation on TPM and its goals, pillars, and other aspects have been explored as well as its relation to 5s, OEE these tools also have been shown. In the end, step by step implementation of TPM is also discussed.
This Project presents a case study in inventory management of Mercedes Spare Parts of a service company. This project aimed to minimize the total costs of the inventory in the company through developing and optimizing various inventory management models of the company’s various spare parts.
Companies that optimize their inventory reduce inventory items and stock levels, avoid associated carrying costs and obsolescence write-downs. Want to know the best practices to optimize your inventory, check the presentation-
Frame and Body of Automobile
Introduction to chassis, Classification of chassis, Conventional chassis,
Semi forward chassis, Full forward chassis, Engine at the front, Engine at the rear, Engine in mid, Frame of the automobile, Function of Frame, types of frame, conventional frame, semi-integral frame, integral frame, defects in chassis, Body of the automobile, types of the body in automobile,
Maintenance Planning and Scheduling are key elements that influence the true success of any organization. Many times we have a planner or planner/scheduler, but do not know how to use him or her effectively or efficiently.
Design and crash analysis of a rollcage for formula sae race careSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Boost Equipment Performance, Save Money With Proactive MaintenanceJames Fitzgerald
Proactive, timely maintenance of plant equipment is critical to enabling manufacturers to meet a dizzying number of demands, from pressure to achieve target output levels, minimize labor costs, control parts spending and ensure maximum uptime. Manufacturers rely on their maintenance departments to help achieve these goals on a daily basis. However, a great number of manufacturers still use maintenance on a reactive basis rather than viewing it as strategic to operations. Myrtle Consulting helps manufacturers convert maintenance into a proactive, scheduled operation that is used strategically to control costs, maximize uptime, and maintain critical equipment. By following a few fundamental principles, plants can begin to establish a maintenance improvement program that supports operations and improves plant performance.
Effective Maintenance Planning and Scheduling is a requirement not an option if one wants to optimize the effectiveness and efficiency of their maintenance workforce. Yes, identifying the right work is key however without effective maintenance planning and scheduling work execution will not be as effective and efficient.
Maintenance Wrench time is directly impacted by the effectiveness of maintenance planning and scheduling (Wrench time is the amount of time a maintenance person has their "hands on tools". World Class ranges from 55-65%)
Maintenance Leading and Lagging Key Performance Indicators (KPIs)Ricky Smith CMRP
“It is not possible to manage what you cannot control and you cannot control what you cannot measure!” (Peter Drucker)
Performance measurement is a fundamental principle of management. The measurement of performance is important because it identifies current performance gaps between current and desired performance and provides indication of progress towards closing the gaps. Carefully selected key performance indicators identify precisely where to take action to improve performance.
This paper deals with the identification of key performance indicators for the maintenance function, by first looking at the ways that maintenance performance metrics relate to manufacturing metrics. Since performance measurements for maintenance must include both results metrics and metrics for the process that produces the results, this document presents a representation for the business process for maintenance. The document then identifies typical business process and results metrics that can be used as key performance indicators for the maintenance function.
Production planning, routing, scheduling, Activating, MonitoringDarshan Shah
First Plan Your Work and then Work on Your Plan.
1. Planning is deciding in advance what to do, how to do it, when to do it and who is to do it.
Planning bridges the gap from where we are, to where we want to go. It makes it possible for things to occur which would not otherwise happen.
2. Routing may be defined as the selection of path which each part of the product will follow, which being transformed from raw material to finished products.
Routing determines the most advantageous path to be followed from department to department and machine to machine till raw material gets its final shape.
3. Scheduling determines the program for the operations. Scheduling may be defined as ‘the fixation of time and date for each operation’ as well as it determines the sequence of operations to be followed.
4. Activating is concerned with the starting the processes. Activating is ‘release of orders and instruction for the starting of production for any item in acceptance with the route sheet and schedule charts’.
5. Monitoring is related to report daily the progress of work in each shop in a prescribed proforma and to investigate the causes of deviations from the planned performance.
Punjab technical University - scheme and syllabus of Masters in Business Administration (MBA) Batch 2012 onwards, course code MBA 202, production & operation Management. UNIT 2, ch.1 Facility Layout ch. 2 Production Planning & Control(PPC), ch.3 Method Study ch. 4 Capacity Planning
Energy Consulting SDVOSB Organizational Assessmentgasanden
Link’s confidentiality policies for current or recent clients prohibit us from releasing client-specific
information. The following Organizational Assessment case study should thus be considered
representative of services that could be provided to support a spectrum of client circumstances.
The Applications section at the end of this document addresses how Link’s Organizational
Assessment practice can be applied to alternative scenarios.
Energy Consulting SDVOSB Organizational AssessmentLink Resources
Link Resources: providing Energy Consulting, Management, Operations and Maintenance services across Fossil, Nuclear, and Bio Energy power plants globally. No SDVOSB has our energy credentials or competencies!
Energy Consulting SDVOSB Organizational Assessmentnatalyabelmont
Link Resources: providing Energy Consulting, Management, Operations and Maintenance services across Fossil, Nuclear, and Bio Energy power plants globally. No SDVOSB has our energy credentials or competencies!"
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
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CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
1.
Empowering ERP Asset Management Solutions
Are your planning and
scheduling processes
using best practices?
Improve asset utilization and
uptime
By Aleks Vujicic, VP Product Management
2. Few people have as much influence on maintenance and reliability as the work
planners and schedulers. They are responsible for establishing the priorities and
ensuring that the maintenance work flow is controlled so that asset utilization and
uptime can be optimized.
Fortunately, there are several steps that can be taken to enhance work planning and
scheduling, improve maintenance and reliability, and enhance operational and
financial performance.
This paper explores the relationship between maintenance and reliability, including
the operational and financial impacts and opportunities. It outlines how to improve
planning and scheduling in a manner that benefits the organization as a whole, using
specific tools, strategies, and best practices. Additionally, it recommends key
performance indicators (KPIs) for measuring and managing performance and
justifying further planning and scheduling improvements.
Opportunities and Enablers
Planning and scheduling processes impact both maintenance and reliability, which
can directly affect uptime. Although these terms are often used interchangeably,
their definitions are distinct. Maintenance refers to the actions necessary to maintain
or restore an item’s operational condition, or to improve its condition, so that it can
fulfill its intended functions. Reliability, on the other hand, is the probability that
equipment, machinery, or systems will perform their required functions satisfactorily
under specific conditions and within a certain time period.
Maintenance productivity is directly impacted by how work is planned and
scheduled. Maintenance managers tend to overestimate the effective maintenance
time of their craftspeople to be 45-55 percent of their day. In reality, analysis has
shown that only 2.5 hours of an eight-hour day represents effective maintenance
time, on average, and it’s worse in locations that are reactive (Figure 1). The balance
of the day is consumed by breaks, cleaning up, waiting for the next assignment,
transit time or, for poorly planned jobs, searching for materials and tools needed to
execute work. With better planning and scheduling, maintenance productivity,
utilization, and effectiveness improves.
Page of2 10
3. Figure 1 Maintenance Productivity (Source: Allied Reliability Group)
Such improvements also help to enhance the overall cost position of the facility
itself. This is best illustrated by the Iceberg Analogy (Figure 2), which shows how
maintenance costs are the “tip of the iceberg” in terms of overall operational
profitability. Obvious maintenance costs such as labor, materials, and contractor
costs are easy to identify and report, while the hidden costs of maintenance (below
the water line) impact process reliability. Unexpected downtime, excessive energy or
water consumption, accidents or quality deficiency costs, for example, typically
won’t roll up to a maintenance budget, but they will impact the operating budget
and financial results.
Figure 2 The Iceberg Analogy: Obvious vs. Hidden Reliability Costs (Source: Allied Reliability Group)
Page of3 10
4. Achieving reliability at world-class costs is imperative to remain competitive, and
maintenance efficiency is a key enabler. With the right maintenance management
system (EAM/CMMS) and sound processes, continuous improvements to asset
designs, repair practices, and maintenance initiatives can reduce preventable
maintenance and improve overall profitability.
The foundation for all maintenance and reliability activities is the work management
system (WMS). In the WMS, work is identified, planned, scheduled and executed,
and the work history is recorded, audited and evaluated. It is a cyclical, continuous
process seeking to improve efficiency and effectiveness through proactive problem
solving and analysis.
Planning Best Practices
The advantage of proper planning is illustrated with a modified probability failure
curve (Figure 3).
When failure conditions are detected early during the asset evaluation or work
planning phase, it allows for adequate planning, scheduling, and execution of
corrective actions well before failure can occur. Predictive maintenance (PdM)
techniques such as vibration analysis support early detection, and since PdM is
typically associated with the most critical pieces of equipment in the organization,
planners must ensure that this work does not go dormant in the backlog.
When conditions are instead found near the end of the probability failure curve,
scheduling must start in earnest to avoid failure. In reactive organizations, 35 percent
or more of the work is emergency or urgent in nature, making it almost impossible to
get ahead on the planning advantage curve. By definition, emergency work breaks
into the current day’s schedule, urgent work breaks in to the current week’s schedule,
and planned work is scheduled for the next week.
Figure 3 The Planning Advantage (Source: Allied Reliability Group)
Page of4 10
5. Many tools and methods exist to optimize and continuously improve the
maintenance planning process. They range from developing job planning steps,
work plans, one-point lesson plans and standard maintenance procedures, to
documenting the bill of materials and improving material and tool organization.
Job planning steps: In high-performing organizations, job planning steps are
documented and followed. Many planners will scoff at this practice, particularly
those who were skilled craftspeople at the plant long before becoming planners.
However, no matter how good they are as planners, the process will suffer when
someone has to fill in for them or replace them. For this reason alone, every
maintenance manager should insist on establishing best practices job planning steps
such as the following:
1. Analyze the work request, ensure there are no duplicates, and get clarity
on the requirements.
2. Visit the job site, bringing a list of all of the equipment to be planned,
all associated work requests, and a mobile device to take photos.
3. Validate the basic information, make edits or corrections if needed, and
take photographs.
4. Plan the work.
5. Determine and ensure the availability of materials, particularly for the
more critical equipment.
6. Complete the work plan.
7. Test for work plan readiness (materials, tools, special equipment, task
lists with all operational steps identified and scheduled hours). The
givens are lockout/tagout and zero energy state information.
Job plans: Work quality is directly affected by the quality of maintenance job plans
(or work packages) provided to the craftspersons. Developing a job plan library
drives consistency in how the work is performed, whether it’s by internal personnel
or service contractors.
Job plans are most useful for work that will be conducted with some degree of
frequency on a particular piece of equipment. Effective job plans are written to the
level of the workforce’s skill and knowledge, and technical jargon should generally
be avoided. They also provide quantifiable details about how to complete the tasks.
For example, a subjective inspection task stating “check gearbox” is not nearly as
helpful as the following quantitative inspection task:
Inspect conveyor gear drive:
• No loose or missing fasteners
• Oil level in the green band on the sight glass
• Oil temperature 160+/- 20F
Page of5 10
6. When quantitative details like these are provided, the time to perform inspections is
minimized, generalities are replaced by facts and data, and a foundation for
continuous improvement is established.
Standard maintenance procedures: SMPs combine job plans and OPL plans into a
planning checklist template with pictures. They are used by planners to ensure that
they have done due diligence on each phase of the planning process. They are also
used by maintenance supervisors to ensure that the packages are assigned to
qualified personnel; by the operations team responsible for readying the asset for
maintenance; and during work execution to validate that every step is completed. At
minimum, the most critical pieces of equipment and the bad actors should have
SMPs.
Bill of materials: The bill of materials (BOM) lists all stock and direct parts associated
with a piece of equipment. Planners can attach BOM parts lists directly to the work
order. An accurate BOM is a time-saving tool, allowing planners and maintenance
workers to find the correct parts within minutes, so that the work can be efficiently
planned and executed. They are not only useful for urgent and emergency work, but
also for executing planned work. In plants where BOMs are not already in use, start
with the most critical pieces of equipment.
5S: 5S is a system to eliminate waste and improve productivity by maintaining an
orderly workplace. It simplifies planning and execution when tool shops, storerooms,
and warehouses use this approach. For example, a tool shop using 5S will have all
tools tagged and identified, with shadow boards to organize the tools. The
maintenance supervisor will have a list of all tools so that replacements can be easily
ordered. And, the space above and below all cabinets will be designed so that it
can’t be filled with clutter. Although 5S takes some time to set up, analysis has
shown that once the system is in place, the areas generally remain orderly.
Parts kitting: Kitting of planned parts is another effective organizational strategy
(Figure 5). All tools and parts needed for a job are packed in a kit, along with an
inventory of the tools and parts contained, so that they are ready when needed.
Work orders should reference the kit location, and a copy of the work order (or the
work order number and equipment number) should be attached to the kit. Color
coding can be used to indicate whether a kit is complete and/or to which crew or
area it belongs. Unused and returned kits should be stored in separate areas.
Scheduling Best Practices
Schedulers organize, prioritize, and create the schedule for the execution of planned
work orders. They leverage the WMS to determine which work is planned and ready
for execution, and to optimize the available workforce. They consider production
Page of6 10
7. requirements, work priorities and budgets when establishing work schedules, and
they monitor crew performance metrics.
The scheduling team should always include the following:
• Planner: The individual who plans and schedules work orders, if the roles
are combined
• Scheduler: The individual who schedules work orders, if separate from the
planner
• Maintenance supervisor: The team leader for a group of workers
• Maintenance coordinator (someone from operations): The link between
maintenance and production
Daily and weekly scheduling meetings are recommended. At the daily meetings,
which should last no more than 10-15 minutes, the team will review the current day’s
schedule and what is breaking in that schedule. It will also track the weekly
maintenance schedule.
On a weekly basis, the scheduling team will look at work that didn’t get done, work
that must be done in the next week, and what work to postpone. They will also
validate the preliminary schedule created by the planner for the following week, and
complete the production priority list.
When selecting work orders from the backlog, priority should be given to the
following:
• Predictive maintenance work orders, e.g., those originating from vibration
analysis
• Preventive maintenance work orders, e.g., inspections
• Work orders to reschedule, which were not completed in the last week
• Work orders prioritized by the scheduling team
• Work orders for critical, bad actor, or bottleneck equipment
• Other corrective work orders
• Equipment modification work orders
Once the schedule is complete, formally communicate and publish it to all affected
resources; even those in the control room who need to purge and cleanse the
equipment and bring it to a zero energy state prior to maintenance.
Finally, schedule coordination must be a formal process, otherwise work execution
will suffer. When emergencies occur, the schedulers will adjust the schedule in real
time, based on current priorities.
They should never make changes to the current weekly schedule; only to the daily
schedule.
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8. Essential KPI’s
Maintenance and reliability performance is quantified and measured using KPIs. If it
is not already being measured, begin with a few basic KPIs and add more when the
maturity of the organization starts to improve. For instance, maintenance efficiency is
measured by the mean time to repair (MTTR) and
reliability effectiveness is measured by the mean time
between failure (MTBF). These two KPIs, in addition to
scheduling compliance, planning compliance and how
much PM and PdM work is being executed, are good
starting points.
Figure 4 WorkAlign Scheduler: Sample screen
True improvements in planning and scheduling will trigger positive trends not only in
maintenance and reliability, but in the operational and financial metrics as well.
Reflecting on the Iceberg Analogy, when maintenance and reliability KPIs trend
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How much of your
budget is consumed by
emergency or urgent
work?
9. positive, the operational and financial KPIs must similarly improve, otherwise it’s time
to rethink what is being planned and scheduled.
Conclusion
Stepping up your planning and scheduling processes is clearly a worthwhile
investment. The upgrades recommended in this paper can be manageable if
applied incrementally. Make sure you’re looking at the WMS to identify work that is
preventable, and place priority on those activities that will prevent failures. Focus
your efforts on the most critical equipment first when developing job plans, SMPs,
BOMs, and kits. Monitor your performance starting with the most important KPIs.
These efforts will pay off not only for the maintenance organization, but for the
company as a whole.
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10. Author
ALEKS VUJICIC
Aleks Vujicic is the VP Product Management at VIZIYA. Aleks has over 20 years of
experience in the maintenance and reliability industry. During his careers Aleks has
gone from being a plant manager at a steel plant, to implementing best of breed
CMMS solutions around the world, and best practise consulting.
About VIZIYA
Headquartered in Hamilton, ON, with offices in Barcelona, Perth, Atlanta and Dubai,
VIZIYA is the industry leader providing bolt-on software products to enhance ERP-
based asset maintenance systems. VIZIYA’s proprietary WorkAlign™ Product Suite
delivers seamless integration into existing ERP systems. With over 45,000 users at
740 sites across 6 continents, the world’s best companies use VIZIYA products to
help them better maintain their assets. Visit viziya.com for more information.