job plan creation best practices (maximo)
TRANSCRIPT
BESTPRACTICESINJOBPLANCREATION
NorthernCaliforniaMaximoUserGroupSantaRosa,CAOctober6,2016MattMidas
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Agenda• Introductions• EAMvsWorldClassMaintenance
• BigData?
• JobPlans
• Whattodo
• TheimpactofJobPlans• Conclusion
• QuestionsandAnswers
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Introduction• USCoastGuardLicensedEngineer–unlimitedhorsepower,steam
anddieselpropulsionplants
• Sailed2yearsonmerchantships(85–86)
• Served3yearsintheNavyasanengineeringofficer–SWO,EOOW,DCA,RPL,CICWO,OODqualified(87–90)
• CharlestonNavalShipyard–repairandoverhaulofS5W/S6Gnuclearreactorplants(90–93)
• PlantoperationsandMaintenanceManagerfor186buildingsinWashingtonDC(93–97)
• PSDI/MROSoftware–solutionsarchitectforMaximo(97–05)
• GenesisSolutions/ABS-MaximoimplementationsandReliabilityimprovements(05–16)
• Solufy–deliveringefficientandsimpletouseplanningandschedulingsolutionsforMaximo(16–__)
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WorkOrders
PlanningvScheduler
vJobPlan
SchedulingvScheduler
AssigningvScheduler
AvailabilityvCalendar
• SeeyourworkordersfromMaximoinoneGantt• Loadthousandsofworkorderseasily• Noneedformultipleschedules• Noimpacttoperformance• Workordersthatmeetyourrequirements• ViewMetricsandComplianceReporting
• Add/Updatecraftrequirements
• Add/modifytasks• SeeresourceavailabilityvJobPlan• Analyze• Create• Update
• QuicklylocateallworkbasedonanydataavailableintheGantt
• Sort,filterorgroupbyanycolumn• Updateormassupdatedata• QuicklyrescheduleWorkOrders• OneClickFiltering• OneClickScheduling• Colorcodedheatmapallowsyouto
seetheimpactofreschedulingworkimmediately
• Defineweeklyordailyschedulesbasedonresourceavailability
AKWIREVisualSuiteforMaximo
Simplified!
• Quicklyfilterworktomatchcraft• Assignresourcesbasedonavailability• Assignresourcestomultiplework
ordersquickly• OneClickAssigningwithDaily
WorkSheet• Allfromthesameapplication!
• Quicklyenterresourceexceptions(vac,sick….)
• UpdatescanbeseeninvScheduler
• Seetrueavailabilityofworkforce
• Accommodatesmulti-shiftandmulti-crewexceptions
• QuicklyandeasilyentertimeinvTimeSheet• MultipleworkordersinExcellayout• Easilyandefficientlyapprovehours
PlanningandScheduling
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EAMvsWorldClass
EAMorWorldClassMaintenance
EAMisthemanagementofassetsacrossdepartments,locations,facilitiesand/orbusinessunits.
ThegoalofEAMisfororganizationstomaximizethereturnoninvestmentfromtheirassetbasebymanagingtheassetthroughoutitslife.
• Acquisition(design,construction,commissioning)
• Operations
• Maintenance
• Decommissioning/ReplacementBenefits
• ImproveAssetUtilizationandPerformance
• ReduceCapitalCosts
• ReduceAsset-relatedOperatingCosts
• ExtendAssetLife
• MaximizeOverallAssetProductivity
• MinimizeTotalCostofOwnership
• Knowwhetheritismorecost-effectivetocontinuetomaintain,overhaulorreplaceafailingasset.
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EAMvsWorldClass
EAMorWorldClassMaintenance
EAMisthemanagementofassetsacrossdepartments,locations,facilitiesand/orbusinessunits.
ThegoalofEAM
• ImproveReliability
• MakeBetterDecisions
• ReduceDowntime
• MoreEffectiveMaintenanceSpend
Benefits
• ImproveAssetUtilizationandPerformance
• ReduceCapitalCosts
• ReduceAsset-relatedOperatingCosts
• ExtendAssetLife
• MaximizeOverallAssetProductivity
• MinimizeTotalCostofOwnership
• Knowwhetheritismorecost-effectivetocontinuetomaintain,overhaulorreplaceafailingasset.
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BigData?• IBMBigDataAnalytics• IoT–InternetofThings
• Watson
• Howdowegetthere?• Welldefinedprocesses• Welldefinedreportingstrategy• Correctlycaptureddata• Standardization• TeamEffort• Supportedfromthetopdown• JobPlans!
• vJobPlan• MPower
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BigData?IoT–InternetofThings• TheInternetofThings(IoT)isthenetworkofphysical
objects,devices,vehicles,buildingsandotheritemswhichareembeddedwithelectronics,software,sensors,andnetworkconnectivity,whichenablestheseobjectstocollectandexchangedata.
• CognitiveIoT:MakingtheInternetofThingsdeliverforallofus
• Allthistogenerateaworkorder–whattoinclude?aJobPlan
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InternetofThings
Assets
Condition
Alarm
WorkOrder
RepairReplace
IoT
JobPlan• Tasks• Labor• Parts• Hours
AnalysisAcquisitionDecommission
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BigDataandReliabilityAReliabilityCenteredMaintenanceProcessanswersthefollowingsevenquestions:
• Whatarethefunctionsandassociateddesiredstandardsofperformanceoftheassetinitspresentoperatingcontext(functions)?
• Inwhatwayscanitfailtofulfillitsfunctions(functionalfailures)?
• Whatcauseseachfunctionalfailure(failuremodes)?
• Whathappenswheneachfailureoccurs(failureeffects)?
• Inwhatwaydoeseachfailurematter(failureconsequences)?
• Whatshouldbedonetopredictorpreventeachfailure(proactivetasksandtaskintervals=JobPlans)?
• Whatshouldbedoneifasuitableproactivetaskcannotbefound(defaultactions=JobPlans)?
Source:SAEJA1011standard
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BigDataandReliabilityIfweunderstandourworkforceavailabilityaswellasthehoursfortheworkwehave,weshouldbeabletobetterscheduleourwork,whichbydefault,willincreaseefficiency.
• JobPlans
• Daily/Weeklyplans
• Shutdowns
• Whomakestheassignments?
• Whomanagesthework?
• Howdoestheworkgetintothetechnicianshands?
• Feedback?
• Compliancereporting?
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JobPlansWhatisthebasicdatayouneedforaJobPlan?• Tasks(DocPalmer’sPlanningPrinciple#5)
• Crafts
• EstimatedHours
• Materials
“AproperlydesignedandexecutedPlanningandschedulingsystemcanbeoneofthemosteffectivemeansavailableinaidingreliabilityinitiativesandinculcatingreliabilitypracticesintothedailyexecutionofmaintenanceactivities.“
RickySmith,CMRP
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JobPlans
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JobPlans
WhatistheperfectJobPlan?• Onethatkeepsimproving
JobPlan
PerformtheWork
Feedback
Updatetheplan
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JobPlans
Stats?• %ofWorkOrderswithJobPlans
• %ofPMswithJobPlans
• Industryaverage
• BestPractice
• Howdetailedshouldweget?• Wantaproblemsolvingworkforce• Carefulnottocreaterobots
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JobPlans
BestPractices• Estimatedhoursbycraft
• Requiredcraftswithskilllevel
• Tasksandsequences(precisionmaintenance–torquespecs,belttension,tolerance,etc.)
• Materials(bytaskifpossible)
• Specialtools• Technicaldocumentation
• Safety–lockout/tagout
• Permits?
• Pictures/drawings
• Consumables
• Physicalorenvironmentalconstraints
• Traveltime?
• Contactatworksite
• Estimatedcostofthejob• Disposalandhousekeeping
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JobPlans
BestPractices• ForwhichassetsdoIcreateJobPlans?
• ShouldIhaveoneJobPlanforeachasset?
• ShouldallworkordersincludeaJobPlan?
• WhoisdevelopingJobPlans• Qualifications• Experience• Trustedadvisor?
• Arerolesandresponsibilitiesclearlydefined?
• Dowehavedocumentedprocessesforplanning?
• Dowehaveafeedbackloop?
• Metrics?
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JobPlans
FuturePerfect§ Wecanonlygettofutureperfectthoughcontinuous
improvement JobPlan
PerformtheWork
Feedback
Updatetheplan
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JobPlans
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Imagineifthisjobplanisreferencedon30PMsthataregeneratedmonthly• 30minutesplanned• 2hoursactual(1.5hourdelta)• 45hoursofunaccountedtime
monthly• 540hoursperyear(foronejobplan)• Isthishandledviaovertime?
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PlanningandScheduling
• Itallcomesdowntoplanningandscheduling• Whatdoesittellus• Who,what,when,where,why,andhow• Resourceavailability• Rightjob,righttime,rightresources• Capturecorrectdata• Reports• Broadcasttheresults
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ImpactofJobPlansSowhat…….whyshouldwehavejobplans?• PartofanEAMProgram
• WorldClassMaintenance
• Unplannedworkis5timesasexpensiveasplannedwork
• Improvesproductivityandassetavailability
• Reducescosts• Improvesreliability
• PAS55/ISO5500–partoftheframework
• Documentstribalknowledge(humancapital)
• Supportsdataanalyticswithmoreaccuratedata
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Conclusion
§ Keepitsimple§ Documentyourprocesses
§ UnderstandthereisnoperfectJobPlanú Itisbettertostartwithsomethingthatcanbeimprovedupon
ratherthanwaituntilyouhaveperfectJobPlanstostart.
§ Continuousimprovementthroughfeedback
§ Definemetricsthataremeaningful§ Usethemetrics
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Conclusion
Assets
Condition
Alarm
WorkOrder
RepairReplace
IoTReliabilityBigData
JobPlan• Tasks• Labor• Parts• Hours
AcquisitionDecommission
