MUWG- Winter 08 Breakout Session 2A

1. MUWG- Winter 08 Breakout Session 2A Standardizing Job Plans And Preventive Maintenance for Optimizing Programs

2. Objectives: Information exchange Understand the importance of Job Plans and why it is important to standardize where possible Review basic rules for PMs to enable an optimization program to be applies

3. PREVENTIVE MAINTENANCEJOB PLANS JOB PLAN PHILOSOPHY Establish When Job Plan is required Define How Job Plan is used Determine Skill level for Plan Establish Labor Estimating Policy Address Material/Parts Requirements Determine How Safety and Environmental issues are addressed Establish Job Plan Controls NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

4. PREVENTIVE MAINTENANCEJOB PLANS When is a Job Plan Required? All PMs All Work on Critical Equipment All Work that requires Materials/Parts All Work that requires pre-job briefing All Work that requires Lock-out All Work that requires multiple crafts All Work that uses hazardous materials All complex work All equipment overhauls/rebuilds NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

5. PREVENTIVE MAINTENANCEJOB PLANS ESTABLISHING WORK CONTENT: Determine how safety and pre-job briefing will be handled Content of Steps and level of detail Tools, tolerances, precautions When to assign time to each step When to reference a procedure or technical manual for the work Rules for equipment restoration Rules for post maintenance testing NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

6. PREVENTIVE MAINTENANCEJOB PLANS ESTABLISHING Naming and Numbering: Important to understand why and how Job plan naming and numbering fits into the work of a Planner Auto number - keep JPs at Org level Naming should allow for associating work content with asset or asset class Naming should define magnitude of work Do not assign priorities to JPs NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

7. PREVENTIVE MAINTENANCEJOB PLANS JOB PLAN LABOR ESTIMATING RULES: All job plans have labor estimates Labor Estimating Business Rules What parts of the job are included/excluded from labor estimates Travel Getting instructions Getting parts Breaks Getting Clearances Job Site Clean-up/restoration NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

8. PREVENTIVE MAINTENANCEJOB PLANS Labor Estimating Business Rules Basis for labor estimates Past performance from actual time reporting Industry or peer experience Internal experienced based Engineered standards Published standards Define who approves work plan estimates and how and when to adjust them Include duration NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

9. PREVENTIVE MAINTENANCEJOB PLANS Labor Estimating Business Rules Labor Requirement Rules Assigning correct number of craft by skill Lead Craft/Crew/Supervisor Minimum Craft Skill Level When to relate Craft to Operational Steps Establishing Labor/Craft Rates (loaded, unloaded) NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

10. PREVENTIVE MAINTENANCEJOB PLANS Job Plan Material Rules All PM Job Plans that require material should have stock or nonstock material (item number) Direct Issue Material Consumables and shop spare need to be in the plan or listed as materials Stock , Non-stock and Special Issue NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

11. PREVENTIVE MAINTENANCEJOB PLANS Job Plan Tool Support Assumes Standard tools available to crafts Listing special tools in the operational step List tools on �Tool Tab� that are listed in the �Resource � Tool� Application Tools that should be scheduled Typically Major tools that are shared such as cranes NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

12. PREVENTIVE MAINTENANCEJOB PLANS Safety Plans, Hazards, Precautions Need to set up rules when to use Safety Plan or include in basic Job Plan Generally list safety hazards and precautions that are above the normally accepted practice for safety Should be used in pre-job briefing and printed on Work Order NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

13. PREVENTIVE MAINTENANCEJOB PLANS Job Plan Summery Well developed Job Plans improve Worker Productivity and Work Quality Need to have well defined rules to ensure Job Plan consistency and quality Job Plan feedback from crafts is essential for a continuous plan improvement NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

14. PREVENTIVE MAINTENANCEJOB PLANS Preventive Maintenance PMs are designed to: Mitigate failures for critical assets Extend life of assets by performing periodic maintenance Ensure regulatory actions for systems or assets are performed to schedule Perform routine tasks associate with good maintenance practices PMs are not: Administrative task Calendar reminders NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

15. PREVENTIVE MAINTENANCEJOB PLANS Preventive Maintenance Optimization Evaluation process to use data from Maximo to adjust PM frequency and work content for the purpose of lowering cost of maintenance without imposing additional risk to the business performance Requires that PM program have rules that enable maintenance staff (engineer) to make program adjustments NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

16. PREVENTIVE MAINTENANCEJOB PLANS Preventive Maintenance Naming and Numbering Naming PM is essential for analysis and provides for standardization � Names should include: Asset name or asset class Magnitude/Scope of work Description of work Sub work type Regulatory Production Safety Environmental NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

17. PREVENTIVE MAINTENANCEJOB PLANS Preventive Maintenance Naming and Numbering PMs should be auto numbered PMs should be associated with assets where possible and locations if assets are not specific to the location Remember that PMs are at the site level NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

18. PREVENTIVE MAINTENANCEJOB PLANS Preventive Maintenance Optimization Maximo set up requirements to help with PM performance analysis Asset priority system that evaluates asset failure probability and consequence Asset Classifications that allow for system wide analysis to eliminate random failure data Failure reporting system codes The use of Follow up work orders for corrective maintenance that result from PM activity NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________NOTES:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________