Maintenance Planning, Scheduling and Control
Strategic planning, scheduling, and control of maintenance to optimize asset performance.
Course Overview
Modern maintenance departments are required to achieve a challenging balance between maximizing asset availability and reliability while simultaneously optimizing maintenance costs. These objectives are inherently conflicting, making structured maintenance planning, scheduling, and control a critical managerial and technical function within asset-intensive organizations.
Maintenance planning and scheduling represent the foundational step toward achieving operational excellence. This function extends beyond the use of project management or computerized maintenance management systems (CMMS) for task sequencing. It encompasses the systematic preparation of work orders, verification of job scopes, assurance of resource availability, coordination of materials and spare parts, and integration of financial evaluation to support cost-effective maintenance decisions.
Effective planning must be followed by disciplined execution and control to ensure that maintenance activities are carried out in accordance with approved plans, organizational policies, and internationally recognized Health, Safety, and Environment (HSE) standards. Proper control mechanisms enable organizations to monitor performance, manage deviations, and continuously improve maintenance effectiveness.
This course presents internationally recognized methodologies, tools, and best practices that enable participants to competently plan, schedule, execute, and control maintenance work orders. By applying these techniques, participants will enhance asset performance, improve maintenance productivity, ensure compliance with safety and regulatory requirements, and contribute to the long-term sustainability and value creation of their organizations.
Course Objectives
By the end of the course, participants will be able to:
- Explain the challenges and objectives facing maintenance organizations today
- Demonstrate the importance of work order systems and use techniques for time estimations and priority assignments
- Prepare a preventive maintenance program
- Apply project management techniques to effectively manage major maintenance activities and shut downs
- Use capital budgeting techniques to evaluate maintenance capital expenditures
- Demonstrate understanding of how to maintain the optimal stock levels of spare parts to ensure operational continuity
- Prepare the right Key Performance Indicators (KPIs) s to evaluate and improve performance in maintenance
Course Audience
Managers, supervisors and planners responsible for maintenance planning, scheduling and control activities.
Course Methodology
Course Outline
Day 1:Fundamentals of Maintenance and Asset Management
- Objectives of Maintenance
- Definition of Maintenance and Asset Management
- Challenges and Objectives of Maintenance
- The Modern Maintenance Strategy
- Maintenance Windows
- Maintenance Methods
- Types of Maintenance
- Classification of Roles in Maintenance
- Customer Service in Maintenance
- The Work Order (WO) System
- Purpose of the Work Order System
- Information Collected on a Work Order
- Job Estimating Methods
- Prioritizing Maintenance Work Orders
- Definition of Preventive Maintenance
- Importance of Implementing a Preventive Maintenance Program
- Establishing Preventive Maintenance Schedules
- Breaking a Facility into Logical Systems and Subsystems
- Developing an Equipment Master List
- Developing and Managing Equipment Manuals
- Inventory Setup to Support Preventive Maintenance
- Risk Assessment Associated with Preventive Maintenance Programs
- Planning and Scheduling of Major Maintenance Work Orders and Shutdowns
- Unique Challenges of Maintenance Shutdowns
- Importance of Clear Work Order Scope Definition
- Work Breakdown Structure (WBS)
- Building an Effective Maintenance Database
- Critical Path Method (CPM)
- Work Order Crashing Techniques
- Resource Scheduling and Resource Leveling
Day 4 : Planning and Control of Maintenance Materials
- Planning and Controlling Maintenance Materials
- Identification of Inventory Costs
- Key Considerations in Maintenance Inventory Decisions
- Economic Order Quantity (EOQ)
- Reorder Point Determination (Minimum and Maximum Levels)
Maintenance Control and Performance Measurement
- Controlling Maintenance Work Execution
- Maintenance Key Performance Indicators (KPIs)
- Backlog Indices
- Schedule Compliance Indices
- Preventive vs. Emergency Maintenance Indices
- Generic Maintenance Performance Indicators
Day 5 : Maintenance Planning, Scheduling, and Performance Improvement
- Role of Planning and Scheduling in Performance Improvement
- Maintenance as a Business Process
- How Poorly Scheduled Maintenance Can Lock in Waste and Cost
- Learning from Repetitive Maintenance Tasks
- Reviewing and Improving Planned Maintenance Activities
- Addressing Maintenance Productivity Challenges
- Refining Maintenance Policies
- Capturing and Utilizing Learning from Inspection Activities
Certificates