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

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Questions

•  MattMidas•  DirectorofSales•  matt.midas@Solufy.com•  443.285.3501

•  www.Solufy.com