All Member Open Forum

 View Only
  • 1.  Maintenance capacity plan/horizon for manufactury industry

    Posted 11-24-2020 10:24 AM
    Dear M&R colleagues, 

    I need to make an estimation of the workforce against the capacity plan, this with the objective of having a horizon or projection of the maintenance plan and to be able to make decisions based on data to improve the maintenance management.
    I already have the activities, procedures, frequencies (weekly, monthly, yearly) and man-hours available.
    Is there any recommendation you can give me? I found some Excel models useful, but they are based on the current maintenance plan and already planned work orders, so it is a quite different approach, as it is not a projection of the planned maintenance (including emergency and corrective works)

    I appreciate any comments that may guide me.

    Jennifer 
    Reliability Engineer

    https://excel-templates.com/maintenance-planning-and-scheduling/

    ------------------------------
    Jennifer Agamez PE
    Cartagena
    ------------------------------


  • 2.  RE: Maintenance capacity plan/horizon for manufactury industry

    Posted 11-25-2020 12:07 PM
    Good Day Jennifer,

    I would request that Craft workers return PM Work Orders with comments to include the actual time it took to complete the work. You can compare this value with the default time value found in the PM or task list if your CMMS is set up that way. Now, you can adjust that time to align with actual work time. This will now have an influence in your work center capacity planning and therefore your look-ahead schedule for 4 to 6 or even 7 weeks out. Keep work center capacity at no more than 80% and in some cases less than that in anticipation of unplanned reactive work of varying priorities. Historical records provide input in future decision making. What is key is to make every effort to keep to the schedule. Easier said than done..

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



  • 3.  RE: Maintenance capacity plan/horizon for manufactury industry

    Posted 11-26-2020 09:21 AM

    Jennifer,

    You are correct in that you must start with yearly workload-based budget, reduce that to monthly and, in turn, to workload work that must be done weekly and daily to sustain the plants productive capacity and asset value. The workload is the annual requirement with respect to different groups such as cost center, work type, lead craft type, etc., that are smoothed in count. The document, Workload-Based Budget Variance and Capacity, at https://analytics4strategy.com/ddassetmgt explains by demonstration how to build your annual budget. It assumes you have skills with working with data. If not the document, Super Tables from Operational Data, explains by demonstration how to work with your data using MS Access.

    There is a practicable way to fit the craft capacity on the ultimate week's schedule. Down from workload-based budget, develop representative weekly schedules of smoothed sustaining workload. Thence, use your scheduling software to arrive at the types and numbers of crafts to execute them. By trial and error, you place different headcounts in the craft pools to see if they allow the representative workload to be fully executed each day. Ultimately, you will arrive at the craft capacity the plant needs to sustain its productive capacity and asset value.

    I'm currently writing the document to deal with weekly scheduling and execution down from the workload-based budget. However, it will not be available until next week.






  • 4.  RE: Maintenance capacity plan/horizon for manufactury industry

    Posted 12-15-2020 08:40 AM
    Edited by Richard Lamb 12-15-2020 08:41 AM

    Jennifer Agamez, some time ago, asked for recommendations with respect to making an estimation of the workforce against the capacity plan. I recommend forming craft capacity in the context of workload-based budgeting and scheduling to sustain productive capacity and asset value.

    Section 12.2.1, Establish Baseline Schedule and Craft Capacity, of the document, Workload-Based Scheduling and Craft Capacity, explains how and the process to formulate craft capacity. It is located at https://analytics4strategy.com/ddassetmgt.



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