THE PLANNING PROCESS
(MICRO PLANNING)
MAINTENANCE PLANNING SCENARIO
The operator of the dehydration plant found high vibration on the water
injection pump P219A. Ada 3 water injection pump yang digunakan
dimana 2 pompa kondisinya running dan 1 pompa stand – by. Bila 2
pompa rusak maka seluruh fasilitas harus di shut in. Seorang teknisi
menemukan bahwa inboard bearing salah satu motor listrik rusak dan
memutuskan mematikan pompa dan menyiapkan spare part. Operator
mengikuti perintahnya dan memberikan informasi tentang motor yang
akan diganti :
Motor size : 200 HP
RPM : 1750
Pump : Gould’s model 3415
Output : 15000 bbls/day
Petunjuk :
1. Tentukan prioritas job
2. Plan and estimate resources needed for this job including :
a. Motor replacement
b. Alignment process
3. Use the planning sheet provided
4. Include major tasks needed to replace and align motor
Asumsi yang diambil :
1. Vibrasi terjadi karena masalah soft foot pada motor
2. Storeroom mempunyai spare motor yang sama
Estimasi resources needed :
1. PPE
2. Equipment and labor
3. Materials and tools
4. Other resources
THE PROCESS OF JOB PLANNING
May include verification of :
1. All aspects of job to be done
2. Various input resources needed
3. Optimal overall cost
The best understanding of this can be achieved by
looking at the criteria of a planned maintenance job
STEPS OF PLANNING PROCESS
1. Specify in advance job that will be planned
2. What has to be done ? Routine, design modification, emergency or
backlog
3. Calculate required budget for the job (For How much)
4. Specify the manner where the job is to be accomplished
(How to do the job)
- Will the work be conducted in house or contractor
be called in or combination of the two (This defines Who is to
do the What)
- Procedures will be used
- Crew skills needed
- HSE necessary
- Tools needed
Finally everyone must know what is going to happen ?
Communicate to all parties involved and management,
The plan of Who is to do the What, How, by When and
for How much ?
Coordinate with the asset custodian (operation) : select
mutual time between maintenance and operation
Schedule the work defining when job will be acted
Ready for execution :
- Supervisor responsibility
- Subordinates
CONDITIONS SUPPORTING
PLANNING PROCESS
1. Complete equipment repair history
2. There is a Maintenance Technical Library
3. Thorough PM or PdM inspection
4. Good use of repair technology
5. Good workmanship by craft personnel
6. Good relationship with vendor
7. Thorough failure analysis
8. Management commitment and support
MAINTENANCE TECHNICAL LIBRARY (MTL)
Place where maintenance planners get information :
1. Equipment maintenance history
2. Equipment manuals
3. Parts list of equipment
4. Assembly drawings, plant drawing and site drawing
5. Internet access
6. Engineering Handbook and textbook
7. Vendor catalog
Access to software systems (CMMS, CAD/CAM, FLUENTS
and ANSYS etc.) should be available in this area
CONSIDERATIONS OF USING MTL
• Protect the paper and computer records from disaster
such as fire, flood and theft
• Use some kind of sign-out system if material must be
removed from the area
• Make it someone's responsibility to keep the records
up to date (in coordination with ISO 900X certification
requirements)
• Manage all revisions so that all copies are updated
(in coordination with ISO 900X certification
requirements)
• Modern CMMS have document management capabilities
COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS (CMMS)
1. Most effective planning and scheduling tool
2. Sequence of events
3. Duration of each event
4. Start and end times of each event
BENEFITS OF USING MTL
1. The planner’s job is simplified and accelerated
2. Job plan resulted are of consistent quality
3. The MTL becomes a universal resource for
maintenance engineering, specification
and problem solving
4. There is a good foundation for further
computer assistance
MTL SHOULD HAVE THESE RECORDS
1. Equipment records
2. Equipment maintenance history
3. Prints, sketches and drawings
4. Labor libraries
5. Materials libraries
6. Purchasing or Stores catalog
7. Files of planned job previously
8. Standard operating procedures (SOP)
9. Other reference sources
A COMPLETE
PLANNING
PACKAGE
MAINTENANCE ORGANIZATION
