Lean Maintenance Planning & Scheduling

3 Day Training

Dates: 24 – 28 February 2025
Locations: Grayston Ridge Office Park, Sandton
Platform: Available In-Class / Online

Limited Seats Available! Book Now to secure your space.

Price: Available on Request

Claim 3 CPD Points

Course Introduction

In the rapidly evolving global business landscape, implementing effective and reliable Lean Maintenance is pivotal for competitive advantage. This Prospen Africa Lean Maintenance Planning & Scheduling course is meticulously crafted to highlight the significance of Lean planning and scheduling in the maintenance domain. By delving into waste elimination, equipment reliability, FMEA, planning, scheduling, and Shutdown Management, the course offers a comprehensive understanding vital for maintenance excellence.

One of the unique features of this training program is the inclusion of practical, hands-on experience. Participants will be provided with over 20 Excel & Kaizen-based templates, enabling them to gain first-hand experience in maintenance planning and scheduling best practices. The course, requiring only basic knowledge in Excel, WORD, and PowerPoint, is designed to be accessible yet deeply informative, with a strong focus on practical application.

Course Objectives

Lean planning and scheduling contribute significantly to the following:

Historical, Present, and Future Perspectives of Maintenance: Offering insights into the evolution and current trends in the maintenance sector.
Lean Maintenance Conceptualization: Understanding lean maintenance through interactive video sessions and group work.
Maintenance Types: Exploring the 12 types of maintenance as developed by the course facilitator.
Role and Purpose of Maintenance Planning and Scheduling: In-depth exploration including practical exercises.
Key Performance Indicators: Understanding and applying Maintenance and Maintenance Effectiveness Indicators (e.g., MTBF, ME, MTTR).
Maintenance Planning Work Process: Focusing on the standardization of planning and scheduling procedures.
Equipment Refurbishment Decision-Making: Analyzing costs and strategies involved in refurbishing equipment.
Scheduling Techniques: Learning about sound scheduling principles, staging parts and tools, and work/job sequencing.
Resource Management: Strategies for manpower and resources scheduling.
Maintenance Measurement with Metrics: Assessing maintenance effectiveness through various metrics.
Motivational Aspects in Planning: Providing 12 motivational tips for effective planning.
CMMS Database Utilization: Specific planning advice for CMMS database integration.
Shutdown Management: Including a comprehensive overview, work identification, and execution strategies.
Practical Tool Exercises: Hands-on exercises for understanding and choosing the most effective project management tools.
Use of Excel Templates: Practical experience with various templates including Gantt, Critical Path, PERT, Budget, Fault Reports, RCA, etc.
Case Studies: Real-world examples for contextual understanding and application.

Who should attend?

This Lean Maintenance Planning & Scheduling course is tailored for a diverse range of professionals including maintenance artisans, supervisors, managers, planners, logistics personnel, plant managers, engineers, project managers, risk management professionals, and financial controllers.

Training Methodology

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.

Training Outline

Day 1: Foundations of Maintenance and Planning

Morning Session: Understanding Maintenance and Lean Principles

Introduction to Maintenance: History, Present, and Future.
Exploring Lean Maintenance: Concepts and Applications.
Introduction to the Author’s Solutions to the 12 Critical Wastes.
Understanding Quality, Productivity, Effectiveness, and Efficiency in Maintenance.

Afternoon Session: Maintenance Objectives, Methodologies, and Strategic Planning

The Purpose and Role of Maintenance Planning and Scheduling.
Failure Mode Effect Analysis (FMEA) and Reliability Basics.
Strategic Importance of Planning in Maintenance: Asset Management Journey.
Equipment Condition Monitoring Practices (with Excel Practice).

Day 2: In-Depth Maintenance Planning

Morning Session: Deep Dive into Maintenance Planning

Detailed Examination of Maintenance Planning and its Components.
Maintenance Performance Prediction Indicators and Equipment Performance Indicators.
Exploring the Job Quality Indicators: QC, QA, and QM.

Afternoon Session: The Work Planning Process

Work Order System and Job Scoping.
PDCA (Plan-Do-Check-Act) Cycle: Practical Excel Exercises.
Estimation of Work Hours, Job Duration, and Resource Management.
Special Tools and Innovations in Maintenance Planning.

Day 3: Advanced Scheduling Techniques

Morning Session: Principles and Techniques of Scheduling

Required Skills for Effective Scheduling.
Critical Path Method (CPM), Bar Charts, Gantt Charts, and PERT Calculations.
Managing the Critical Path and Advanced Scheduling Concepts.

Afternoon Session: Implementing and Managing Schedules

Weekly Scheduling: Forecasting, Sorting, and Allocating Work Orders.
Staging Parts and Tools: Process and Strategy.
Work Scheduling and the 12 Steps to Successful Scheduling.
Practical Exercises and Group Work on Scheduling Techniques.

Throughout the Course:

Practical Exercises: Hands-on experience with over 20 templates.

Group Work and Discussions: Collaborative learning and idea exchange.

Case Studies: Real-world applications and problem-solving.

Course Materials and Requirements:

Soft Copy Templates: Excel & Kaizen based.

Requirement: Laptops with Windows 2003 – 10&11and basic knowledge of Excel, WORD, and PowerPoint.

Accreditation and Certification:

SAAMA Accredited: 3 CPD Points.

This structured approach ensures that the course is comprehensive, covering all necessary areas while allowing participants to progressively build on their knowledge and skills over the three days.