All Member Open Forum

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc. 

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Hello Darrell,

I don't have the Dow study, but here is an idea.  

1.  Add up all current maintenance hours per year (Own + OT + Contract).  If you can't get contractor hours, use 30% of spend... it seems to be accepted.  Let's say you use 200,000 mtce hrs per year.

2. Assumption.  1. You are currently Plan and schedule 25 % of the work (or whatever # u choose, will be depending on definition of what a planned and scheduled job is).  This means you have 75 unplanned Unscheduled work​.  Assumption 2... conservative.  When you have an unplanned & unschedule job you waste 50% of the time.  I think it is more like 75%, but most would buy 50%  (Compare NASCARE tire change with your own).

3.  How much mtce hours are u wasting today?  200,000 x 75% x 50%=  75,000 hrs 

4.  Assumption:  We can go to 60% planned an schedule in 2 years.  Then we would "only" have 40% unpl. & Unsch.

5.  In the future we would waste:  200,000 x 40% x 50% = 40,000 hrs

Business case... $50/ hr x (75k-40k)= 1,750,000/ year.

U may not like my assumptions, but u see the business case logic?

Note!  The biggest financial gain is from increased production while keeping fixed cost the same, it is true for your industry as long as you can sell all you make.

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC
------------------------------

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

​Thanks, Torbjorn.  This is good info.  Now, I just need some scholarly references to base my assumptions upon.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Original Message:
Sent: 04-16-2020 07:52 PM
From: Torbjorn Idhammar
Subject: Planning and Scheduling

Hello Darrell,

I don't have the Dow study, but here is an idea.

1.  Add up all current maintenance hours per year (Own + OT + Contract).  If you can't get contractor hours, use 30% of spend... it seems to be accepted.  Let's say you use 200,000 mtce hrs per year.

2. Assumption.  1. You are currently Plan and schedule 25 % of the work (or whatever # u choose, will be depending on definition of what a planned and scheduled job is).  This means you have 75 unplanned Unscheduled work​.  Assumption 2... conservative.  When you have an unplanned & unschedule job you waste 50% of the time.  I think it is more like 75%, but most would buy 50%  (Compare NASCARE tire change with your own).

3.  How much mtce hours are u wasting today?  200,000 x 75% x 50%=  75,000 hrs

4.  Assumption:  We can go to 60% planned an schedule in 2 years.  Then we would "only" have 40% unpl. & Unsch.

5.  In the future we would waste:  200,000 x 40% x 50% = 40,000 hrs

Business case... $50/ hr x (75k-40k)= 1,750,000/ year.

U may not like my assumptions, but u see the business case logic?

Note!  The biggest financial gain is from increased production while keeping fixed cost the same, it is true for your industry as long as you can sell all you make.

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

I haven't seen the Dow industries numbers, however I would highly recommend Doc Palmer's, Maintenance Planning and Scheduling Handbook.  He has numerous case studies on how Planning and Scheduling increase productivity with a similar workforce.  He also shows calculations as to how having Planners/Schedulers can prove a business case of completing 47 technicians worth of work with 30.  Its a good read for development of a process and also gives some insight on the affects of RCM. Hope it helps.

------------------------------
Michael Guns, Jr., CRL
Associate Director, Maintenance Strategy and Planning
Facilities - Buildings Maintenance & Operations
200 Academy Street - Newark, DE 19716
Maintenance Center - Room 113
Office: 302.831.4055 Cell: 302.358.9381
------------------------------

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

​Thanks, Michael.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Original Message:
Sent: 04-17-2020 07:26 AM
From: Michael Guns
Subject: Planning and Scheduling

I haven't seen the Dow industries numbers, however I would highly recommend Doc Palmer's, Maintenance Planning and Scheduling Handbook.  He has numerous case studies on how Planning and Scheduling increase productivity with a similar workforce.  He also shows calculations as to how having Planners/Schedulers can prove a business case of completing 47 technicians worth of work with 30.  Its a good read for development of a process and also gives some insight on the affects of RCM. Hope it helps.

------------------------------
Michael Guns, Jr., CRL
Associate Director, Maintenance Strategy and Planning
Facilities - Buildings Maintenance & Operations
200 Academy Street - Newark, DE 19716
Maintenance Center - Room 113
Office: 302.831.4055 Cell: 302.358.9381

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

​

------------------------------
John Cray
Life Cycle Engineering
N. Charleston SC
------------------------------

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------
​

​Thanks, John.  Do you know if the book has data or case studies that I can back up my assumptions?

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Original Message:
Sent: 04-17-2020 08:52 AM
From: John Cray
Subject: Planning and Scheduling

There are many great books, I am partial to:

Maintenance Planning and Scheduling: Streamline Your Organization for a Lean Environment 1st Edition

by Timothy C. Kister (Author), Bruce Hawkins (Author)

John

​

------------------------------
John Cray
Life Cycle Engineering
N. Charleston SC

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------
​

HI Darrell:
Here's a couple papers that were presented at the 2008 SMRP Annual Conference on ROI for reliability improvement strategies.  Making Common Sense Common Practise by Ron Moore is a good reference as well.   The data from the DOW Chemical example you mentioned was interesting to me, although i never got my hands on the actual report i did find that the breakdown that Winston Ledet used in his Manufacturing Game (which references the Dow improvements) was close to my own experience.  e.g.   Dow had around an 18% improvement in plant availability with their global project for reliability improvement .  around 10% of it was due to RCA and problem elimination.  the other 8% was split equally between planning and scheduling and PM improvements.  Eliminating recurring downtime is the biggest payback as it increases throughput (if you have the demand) and spreads fixed costs.   
all the best
Rob Probst CMRP

------------------------------
Rob Probst
Skills4Work Limited
Ohope
------------------------------

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

​Thanks, Rob.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Original Message:
Sent: 04-20-2020 09:00 PM
From: Rob Probst
Subject: Planning and Scheduling

HI Darrell:
Here's a couple papers that were presented at the 2008 SMRP Annual Conference on ROI for reliability improvement strategies.  Making Common Sense Common Practise by Ron Moore is a good reference as well.   The data from the DOW Chemical example you mentioned was interesting to me, although i never got my hands on the actual report i did find that the breakdown that Winston Ledet used in his Manufacturing Game (which references the Dow improvements) was close to my own experience.  e.g.   Dow had around an 18% improvement in plant availability with their global project for reliability improvement .  around 10% of it was due to RCA and problem elimination.  the other 8% was split equally between planning and scheduling and PM improvements.  Eliminating recurring downtime is the biggest payback as it increases throughput (if you have the demand) and spreads fixed costs.
all the best
Rob Probst CMRP

------------------------------
Rob Probst
Skills4Work Limited
Ohope

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Hi Darryl,

A number of years ago, Ron Moore presented at the annual SMRP conference.​ The attached file may have what you are looking for or close to it. Also, I would recommend reading Maintenance Work Management Process by Terry Wireman, particularly Chapter 4.

Enjoy,

------------------------------
Ed Espinosa, CMRP, CRL
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA
------------------------------

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Ed,
I would caution against hanging our hat on the charts of injuries to maintenance types in the slides. The correlation and regression coefficients indicate that the relationship between corrective-reactive to injuries is much more complex than can be seen in the chart. Other variables play such that simple correlation does not tell the story. What needs to be tested is the unique correlation after removing shared correlation to injuries. Maybe what we are seeing is that corrective maintenance is the ultimate outcome of all maintenance strategies, whereas, the proportion of scheduled maintenance is a decision. Recall that all scheduled proactive maintenance at some time reveals a need for corrective maintenance. Only PM--as scheduled work over or disposal--has its own "corrective" task.

Chapter 3 of the book, "Data Driven Asset Management," ( download at https://analytics4strategy.com/ddassetmgt) to teach the software R used a set of data with the same characteristics--two predictive variables associated with a third outcome variable.  With what is shown anyone can substitute the data points of slides 7 and 8 to text for unique correlation and significant regression coefficients. Furthermore, the chapter as a tool can be used for many investigations.

Richard Lamb


------------------------------
Richard Lamb
Analytics4strategy.com
rchrd.lamb@gmail.com Houston TX
http://analytics4strategy.com
------------------------------

Original Message:
Sent: 04-22-2020 10:21 AM
From: Edward Espinosa
Subject: Planning and Scheduling

Hi Darryl,

A number of years ago, Ron Moore presented at the annual SMRP conference.​ The attached file may have what you are looking for or close to it. Also, I would recommend reading Maintenance Work Management Process by Terry Wireman, particularly Chapter 4.

Enjoy,

------------------------------
Ed Espinosa, CMRP, CRL
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

​Big thanks, Ed.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Original Message:
Sent: 04-22-2020 10:21 AM
From: Edward Espinosa
Subject: Planning and Scheduling

Hi Darryl,

A number of years ago, Ron Moore presented at the annual SMRP conference.​ The attached file may have what you are looking for or close to it. Also, I would recommend reading Maintenance Work Management Process by Terry Wireman, particularly Chapter 4.

Enjoy,

------------------------------
Ed Espinosa, CMRP, CRL
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Huge thanks.​

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------

Original Message:
Sent: 04-22-2020 10:21 AM
From: Edward Espinosa
Subject: Planning and Scheduling

Hi Darryl,

A number of years ago, Ron Moore presented at the annual SMRP conference.​ The attached file may have what you are looking for or close to it. Also, I would recommend reading Maintenance Work Management Process by Terry Wireman, particularly Chapter 4.

Enjoy,

------------------------------
Ed Espinosa, CMRP, CRL
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA

Original Message:
Sent: 04-16-2020 05:51 PM
From: Darrell Walker
Subject: Planning and Scheduling

​​If I remember, I have seen references to a Dow study that had data on the ROI of proactive maintenance strategies, particularly planning and scheduling.  I am building a business case and need to reference studies that show potential savings on efficiency gains from planned work, PMs vs. PdMs/Precision, RCM vs Rebuild, etc.

Does anyone have access to case studies or access to data from either the Dow study, the Airline Industry, etc.  Alternatively, books or articles by influencers that have referenced data would be helpful.

Big thanks.

------------------------------
Darrell Walker
Manager of Maintenance and Reliability
Amalgamated Sugar Company
Boise ID
------------------------------