Efficient work preparation and planning for stops and shutdowns
This three-day training course covers the benefits of work preparation and planning. You will learn how to synchronise your work preparation and planning processes for your daily maintenance and shutdowns, how to get the most out of your maintenance team by increasing effectiveness and performance, and how to take important steps in your shutdown processes.
Reacting to breakdowns, preparing work, being on schedule for your preventive maintenance, preparing for downtime and executing it within the given time... Every maintenance department operates in a demanding and challenging environment, often with shrinking teams. Yet in many companies there is still room to do more work with the same number of people, by preparing and planning more effectively.
The more we can reduce the time spent searching for parts, tools or drawings, and the more we can reduce the time spent waiting for jobs to be assigned, the more we can efficiently deploy our maintenance team and monitor and streamline the production process.
This three-day training course covers the benefits of work preparation and planning. You will learn how to synchronise your work preparation and planning processes for your daily maintenance and shutdowns, how to get the most out of your maintenance team by increasing effectiveness and performance, and how to take important steps in your shutdown processes. In this course, you will learn about both routine maintenance and periodic line stops.
The course also includes an interactive game called 'I-Plan', in which you experience the principles of an efficient stop yourself.
In teams, the participants have to simulate the shutdown process from initiation to evaluation. This simulation approaches reality in the most unexpected details. I-Plan is an exciting and interactive simulation that imitates a real shutdown with all the typical problems such as parts management, resource constraints, quality problems, subcontractor problems, planning challenges, work order management etc. On a game board, where logistics and safety related constraints stand in their way, they have to prepare and plan the workload with different interactive assets and demarcated zones. Delineating and managing the critical path is also included in the game. They do this in a race against time, because... 'Time is money'!
Learning objectives
- Know the core values and benefits of work management
- Know the different roles and responsibilities
- Know the different steps in work management
- Know the benefits of work order analysis and continuous improvement
- Create the content of a task plan
- Calculate backlog
- Master the routine planning process
- Know the differences between routine and downtime work management
- Know the critical path
- Know the risks of downtime
- Know the different phases of the downtime process
- Know how to measure and evaluate a work order and downtime process
Programma
Advantages of the process
- Terminology
- Beliefs
- Waste in the process
- Key Time or Wrenchtime
Roles and responsibilities
- What is the added value of a planner
- What does a planner NOT do
- Coordinating work preparation and planning
- Activity
Identifying, controlling and managing work
- Sources of work
- Formally report on work
- The content of a work request
- Types of work
- Priorities
- Emergency work order protocol
- Checking work requests
Work preparation/ job plans
- Standard work and job plans
- Subjective vs. quantitative tasks
- Job plan content checklist
- Standard work library
- Tips for job plans
- Activity
Priorities and backlog
- Why priority
- Work prioritisation checklist
- Task: priorities
- Calculate and quantify the Backlog
- How do we deal with Backlog?
- Exercise: Calculate Backlog
Routine Planning
- Principles
- Some planning rules
- Planning horizon
- Planning timeline
- Planning team
- Activity
Performing work
- Coordinating daily work
- Shift surrender
- Following up on work orders
- Closing and feedback
- Auditing work output
KPIs
- % prepared vs % unprepared work
- PM/PdM Balance
- Backlog
- Key time (Wrenchtime)
- % estimated vs. actual hours
- % working hours planned
- Conformance to plan
The characteristics of a shutdown and how to prepare for it
- Planning horizon
- Successful shutdowns
- Best practice examples
- Goals
- The fundamentals
- Shutdown management and improvement
Shutdown planning
- Time horizon
- The differences with routine plans
- The critical path
- Slack / float
- PERT
- Task Compression
Downtime risk management
- Triggers
- Countermeasures
- Risk Avoidance
- Risk Recovery
- Risk Analysis
Treating downtime as a process
- Prepare and optimise downtime
- Identify
- Organise
- Check
- Execute the shutdown
- Review and Close Downtime
- Improve
About the trainer
Guido Verrept has been active as a trainer and improvement coach for more than 30 years. Helping companies and their employees to get a step ahead in their goals is his main motivation. Guido started his career as a design engineer at Atlas Copco, before joining ABB as Maintenance Manager. As a teacher Guido has been active all over the planet: from Australia and Africa to Brazil and of course Europe. Within the unified I-care, Guido is Performance & Compliance Officer since 2021.
Who is this training for?
This training is suitable for Maintenance Managers, Work Planners and Planners as well as Maintenance Supervisors and Shutdown Managers. Also everyone who already has experience with stops and wants to improve his working methods is welcome.
Graag min. 14 dagen voor de start inschrijven. PO kan later bezorgd worden.
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