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How can you improve plant maintenance scheduling?

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Plant maintenance scheduling is a crucial task for any manufacturing facility. It ensures that the equipment, machinery, and systems are operating at optimal levels, reducing downtime, waste, and costs. However, many manufacturers struggle with finding the best way to plan, execute, and monitor their maintenance activities. In this article, you will learn some practical tips on how to improve your plant maintenance scheduling and achieve better results.

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Lucas Roesler

Managing Director at UNICORR Limited UK and Printtek Poland.

1 Assess your current situation

The first step to improve your plant maintenance scheduling is to evaluate your current state. You need to collect and analyze data on your assets, such as their condition, performance, availability, and reliability. You also need to identify the types and frequencies of maintenance tasks that are required, such as preventive, predictive, corrective, or condition-based. This will help you understand your maintenance needs, priorities, and challenges.

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2 Choose a suitable strategy

The next step is to choose a maintenance strategy that suits your plant's goals, resources, and constraints. There are different approaches to plant maintenance scheduling, such as time-based, usage-based, condition-based, or reliability-centered. Each one has its advantages and disadvantages, depending on the factors such as the criticality, complexity, and variability of your assets. You should compare the benefits and costs of each strategy and select the one that maximizes your plant's efficiency, quality, and safety.

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Prince Chika Onwuajuese

Results-Driven Mechanical Engineer | Expertise in Plant Commissioning & Maintenance | Business Development | Logistics Management | Seeking Opportunities to Drive Organizational Success
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Have a plan. How long is this equipment supposed to run before a PM is carried out on it. This information comes from the OEM, having known this, plan your maintenance so as not to have a production downtime.

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3 Implement a software solution

The third step is to implement a software solution that can help you automate and optimize your plant maintenance scheduling. A software solution can provide you with features such as asset management, work order management, inventory management, scheduling optimization, performance tracking, and reporting. A software solution can also integrate with other systems, such as sensors, PLCs, ERP, or CRM, to collect and share real-time data on your assets and operations. This will enable you to make informed and timely decisions on your maintenance activities.

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Peter Le

Director
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Implement a CMMS (Computerised Maintenance Management Systems) software to streamline maintenance scheduling, track work orders, manage spare parts inventory, and generate reports for better decision-making. It would be helpful to provide a list of suitable software solutions in the format of Computerised Maintenance Management Systems (CMMS) 1- IBM called Maximo can automate and optimise your plant maintenance system and more 2- Fiix is a cloud-based computerized maintenance management system (CMMS) 3- Oracle Supply Chain Management (SCM) With Oracle Supply Chain Management (SCM) & Manufacturing.

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4 Train and engage your staff

The fourth step is to train and engage your staff in your plant maintenance scheduling process. Your staff are the ones who perform, monitor, and report on the maintenance tasks, so they need to have the skills, knowledge, and motivation to do so effectively. You should provide them with regular training on the maintenance procedures, standards, and best practices. You should also communicate with them clearly and frequently about the maintenance goals, plans, and expectations. Moreover, you should encourage them to provide feedback and suggestions on how to improve the maintenance process.

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5 Review and improve your process

The fifth step is to review and improve your plant maintenance scheduling process on a regular basis. You should measure and evaluate the outcomes and impacts of your maintenance activities, such as the availability, reliability, and productivity of your assets, as well as the maintenance costs, quality, and safety. You should also identify the gaps, issues, and opportunities for improvement in your maintenance process. Then, you should implement the necessary changes and adjustments to your maintenance strategy, software, staff, or procedures to enhance your plant maintenance performance.

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Peter Le

Director
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This fifth step can be carried out effectively if you have Standardised Maintenance Procedures. Standardise maintenance procedures and documentation to ensure consistency, improve efficiency, and facilitate training and knowledge transfer among maintenance personnel before you make further improvements on your plant maintenance scheduling process.

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6 Follow the best practices

The sixth and final step is to follow the best practices for plant maintenance scheduling. This includes aligning your maintenance objectives with your plant's strategic goals and customer needs, as well as prioritizing your maintenance tasks based on the risk, impact, and urgency of your assets. Additionally, you should balance your maintenance resources, such as labor, materials, and tools, with your maintenance demands. It is also important to coordinate your maintenance activities with production schedules and other plant functions. Furthermore, you should document and standardize your maintenance processes and procedures, while leveraging the latest technologies and innovations to improve your maintenance capabilities and efficiency.

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Lucas Roesler

Managing Director at UNICORR Limited UK and Printtek Poland.
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Generally I agree with conclusions. However we need to remember, there’s no one universal rule regarding all equipment we use everyday in our fabrics. Above list must be verified and adapted to existing production lines, but it should also be applied to equipment used by our maintenance or engineering teams. From my own experience, I must say, there’s no bigger disappointment than to see a maintenance guys with tools which TUV certificates expired. So, as long as we keep our workshops well maintained, we can proceed with maintenance at professional level.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Peter Le

Director
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- Empower maintenance teams with the training, tools, and resources they need to perform their jobs effectively, including access to equipment manuals, safety protocols, and technical support. - Monitor Key Performance Indicators (KPIs). Track and monitor key performance indicators such as mean time between failures (MTBF), mean time to repair (MTTR), equipment uptime, and maintenance costs to evaluate the effectiveness of maintenance scheduling and identify areas for improvement.

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How can you improve plant maintenance scheduling?

1

2

3

4

5

6

7

1 Assess your current situation

2 Choose a suitable strategy

3 Implement a software solution

4 Train and engage your staff

5 Review and improve your process

6 Follow the best practices

7 Here’s what else to consider

Manufacturing

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How can you improve plant maintenance scheduling?

1

2

3

4

5

6

7

1 Assess your current situation

2 Choose a suitable strategy

3 Implement a software solution

4 Train and engage your staff

5 Review and improve your process

6 Follow the best practices

7 Here’s what else to consider

Manufacturing

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