Maintenance Planning

Maintenance Planning is the crucial preparatory phase of maintenance management. It involves determining what maintenance tasks need to be performed and how they should be executed before the work actually begins. It's about thinking through the job in advance to ensure it can be done efficiently, safely, and effectively.

Definition:

• Maintenance Planning involves analyzing required maintenance work and establishing the methods, procedures, tools, materials, and labor required to perform that work.

Purpose of Maintenance Planning:

• Ensure Preparedness: Guarantees that all necessary resources (parts, tools, labor, information) are identified and available before the job starts, minimizing delays.
• Improve Efficiency: Allows work to be performed more efficiently by defining clear steps and methods, reducing wasted time and effort during execution.
• Enhance Safety: Enables potential hazards to be identified and safety precautions planned in advance.
• Optimize Resource Use: Helps allocate the right skills, tools, and materials for the job.
• Facilitate Scheduling: Provides the necessary information (tasks, estimated times, resources) needed for effective scheduling.
• Cost Estimation: Allows for better estimation of labor and material costs for maintenance tasks.

Key Questions Answered by Planning:

• What work needs to be done? (Scope, specific tasks)
• Why is the work necessary? (PM, breakdown, improvement)
• How should the work be performed? (Step-by-step procedures, methods)
• What resources are needed? (Labor skills, number of people, materials, tools, special equipment)
• Where will the work be done? (Location, access)

Steps in Maintenance Job Planning:

1. Work Identification & Scope: Clearly define the maintenance task required (from work requests, PM schedules, inspections). Visit the site if necessary to understand the full scope.
2. Procedure Development: Outline the sequence of steps needed to complete the job safely and correctly. This might involve referencing manuals or creating specific instructions.
3. Resource Identification:
   • Labor: Determine the number of people and specific skills (e.g., electrician, mechanic, welder) required.
   • Materials: Identify all spare parts, consumables (lubricants, seals), and raw materials needed. Check availability.
   • Tools & Equipment: List standard and special tools, lifting equipment, safety gear, testing instruments required.
4. Time Estimation: Estimate the labor hours required for each step or trade, and the overall duration of the job. This often uses standards, historical data, or experience.
5. Safety Precautions: Identify potential hazards and specify necessary safety procedures (e.g., lockout/tagout, permits, personal protective equipment - PPE).
6. Coordination Needs: Determine if coordination with other departments (e.g., production for equipment shutdown, safety department for permits) is required.
7. Documentation: Compile the plan into a work order package containing procedures, parts lists, safety requirements, and drawings if needed.

• Indian Example: Planning a major scheduled maintenance shutdown (overhaul) at an NTPC thermal power plant requires extensive effort. Planners determine exactly what turbines, boilers, and generators need servicing (scope). They develop detailed procedures (how) for disassembly, inspection, repair, and reassembly. They identify requirements for specialized labor (internal and contractors), materials (large bearings, turbine blades, seals), and heavy equipment (cranes). Time estimation using tools like PERT/CPM is crucial for the shutdown duration. Safety planning is paramount due to the high risks involved. This detailed planning ensures the shutdown is executed efficiently and safely within the planned timeframe.

Effective planning transforms maintenance from a reactive scramble into an organized, efficient, and controlled process.