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Maintenance operations in the busy environment of facility management tend to degenerate into a frantic fire-fighting process. In cases where machines suddenly malfunction, the production process comes to an abrupt stop, and the technicians are in a rush.
A systematic method in maintenance planning and scheduling is the best medicine for this responsive anarchy. These two different disciplines operate together to ensure that your department is a proactive profit generator, although they are often used interchangeably.
This guide is going to deconstruct the essential distinctions between the planning of work and the scheduling of resources. We also will map out steps that can be taken and best practices that are available in the industry to fully optimize your maintenance operations.
Planning vs. Scheduling: What’s the Difference?
The Core Distinction
The most concise way to differentiate the two is by the questions they answer:
- Planning: It involves determining exactly what work needs to be done and the best method to accomplish it. It prepares the job, so the technician does not face delays after assignment.
- Scheduling: It involves determining the timing of the work and assigning specific personnel to execute it. It organizes work to reduce delays between jobs.
Maintenance Planning: Preparing the Job
Planning refers to the preparation that is done on work orders in advance of their being allocated to craftspeople. The main aim of it is to make sure that when a crew is given job, he/she is ready to go with task without wasting time searching parts, tools or instructions.
- Key Activities: include the scoping of work, identification and reservation of the required resources (spare parts, tools), labor hour estimation, and the examination of the feedback of the past jobs.
- The "Future Work" Principle: Future work or the work yet to be created needs the attention of the planners. They are not supposed to be engaged in troubleshooting of jobs that are already in progress (with the exception of often known as chasing parts).
- Output: A work plan or work package which is in detail that serves as a head start to the technician.
The Benefits of Getting It Right
Implementing a structured planning and scheduling system is not just about organizing paperwork; it is a strategic business decision. The benefits fall into several distinct categories:
Dramatic Increases in Workforce Productivity
Without planning, technicians typically spend only 25% to 35% of their day actually working on equipment (known as "wrench time").
- The "Free" Technicians: By implementing proper planning, you can increase wrench time to 50% or 55%. In a crew of 30 technicians, adding a single planner can boost productivity to equal that of 47 technicians working without a planner. This 1.57 leverage factor effectively grants you extra labor power without hiring a single new person.
Reduced Downtime and Improved Reliability
- Minimized Disruptions: Scheduling will enable tasks to be undertaken at off-peak times or during scheduled close time.
- The "Melting" Backlog: When crews are more efficient, the accumulation of work slows down or disappears altogether, and the backlog of work tends to be low in these organizations that deploy these systems. Maintainable plant capacity will guarantee that no revenue will be lost.
The CMMS Advantage
Using Computerized Maintenance Management System (CMMS) software acts as a force multiplier. It provides data for metrics like "Schedule Compliance," links parts to specific work orders for inventory control, and institutionalizes knowledge, so teams never have to "reinvent the wheel."
5 Steps to Effective Maintenance Planning
Transforming a work order from an initial request to a ready-to-execute job involves a systematic approach:
1. Identify the Problem and Create a Work Order
Capture the initial issue by generating a formal work order that clearly details the specific problem, location, and asset.
2. Inspect the Asset and Premise (Scoping)
Conduct a physical site visit to accurately diagnose the problem, verify required technician skills, and identify any safety or accessibility constraints.
3. Order Parts and Prescribe a Process (The Work Plan)
Build a comprehensive work package that provides the technician with step-by-step instructions, safety protocols, and all necessary replacement parts.
4. Assign a Priority Level
Categorize the task's urgency based on asset criticality to ensure high-value production equipment receives immediate attention over non-essential tasks.
5. Schedule and Complete the Work
Place the prioritized job on the weekly schedule for execution and collect post-job feedback to continuously improve your future maintenance plans.
Best Practices for Maintenance Scheduling
- Embrace Core Scheduling Principles: Have an elaborate plan on every job, have all the available labor hours put in place to make a base of productivity and follow the weekly schedule to the letter unless a genuine emergency occurs.
- Optimize the Weekly Workflow: Preplan the labor hours available by the supervisors and then prioritize the ready to schedule backlog by priority and equipment position to use as much wrench time as possible.
- Empower Daily Coordination: Although the scheduler establishes the weekly objectives, the empowerment of crew supervisors with daily allocation, and the possibility of responding to urgent and critical failures in real-time.
- Stage Parts and Tools (Kitting): Prepare all the necessary parts and special tools before the working week starts to eliminate waiting time in the storeroom.
- Measure Schedule Compliance: The percentage of scheduled work completed should be measured regularly to determine the efficiency of the workforce and areas to improve.
Your Strategy with Cryotos CMMS Software
Raise your maintenance strategy and practice these best practices without a struggle by relying on the Cryotos CMMS Software.
- Visual Maintenance Scheduling: Assign tasks easily and prevent conflicts with our calendar-based interface.
- Automated Work Order Management: Generate, monitor and attach highly detailed work orders to the mobile devices of your technicians automatically.
- Resource & Inventory Control: The seamless integration of labor placement and spares is carried out to prepare all of it and be prepared when a job commences.
- Data-Driven Insights: Monitor the key metrics such as Schedule Compliance and Wrench Time with customizable BI dashboards to continually develop your strategy.
Conclusion
The art of maintenance planning and schedule will turn reactive extremes into proactive and efficient activities. The preparation and assignment of work will become much quicker at your facility, which will significantly increase wrench time and asset life.
Are you willing to cease paying unplanned downtime? Learn how Cryotos CMMS will help you automate your scheduling to the maximum possible productivity and to help defend your bottom line.
