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