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What are the best practices for scheduling maintenance tasks in a manufacturing facility?

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Maintenance tasks are essential for keeping a manufacturing facility running smoothly and efficiently. However, they can also be disruptive, costly, and time-consuming if not planned and scheduled properly. In this article, you will learn some of the best practices for scheduling maintenance tasks in a manufacturing facility, using critical thinking skills to optimize your decisions and outcomes.

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Roger Borycki

Helping Companies Improve | Reliability | Operations | Maintenance | Engineering

1 Identify your maintenance goals

Before you start scheduling your maintenance tasks, you need to have a clear idea of what you want to achieve with them. For example, do you want to prevent breakdowns, improve quality, reduce waste, or comply with regulations? Your maintenance goals should align with your overall business objectives and reflect your priorities and constraints. You can use a SMART framework to define your maintenance goals, making sure they are Specific, Measurable, Achievable, Relevant, and Time-bound.

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2 Assess your maintenance needs

Once you have your maintenance goals, you need to assess your maintenance needs, which are the activities and resources required to meet your goals. You can use various methods to evaluate your maintenance needs, such as inspections, audits, risk assessments, performance indicators, or feedback from operators and customers. You should also consider the types and frequencies of maintenance tasks, such as preventive, predictive, corrective, or adaptive. You should aim to balance your maintenance needs with your available resources, such as staff, equipment, materials, and budget.

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3 Prioritize your maintenance tasks

After you have identified your maintenance needs, you need to prioritize your maintenance tasks, which are the specific actions and steps that you will perform to fulfill your maintenance needs. You can use various criteria to prioritize your maintenance tasks, such as urgency, impact, cost, duration, or complexity. You should also factor in the dependencies and interdependencies of your maintenance tasks, such as the sequence, availability, or compatibility of the tasks. You should aim to prioritize your maintenance tasks based on their value and risk for your facility.

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4 Schedule your maintenance tasks

Once you have prioritized your maintenance tasks, you need to schedule your maintenance tasks, which are the dates and times that you will execute your maintenance tasks. You can use various tools to schedule your maintenance tasks, such as calendars, spreadsheets, or software applications. You should also consider the constraints and opportunities of your schedule, such as the production demand, the downtime, the flexibility, or the contingency. You should aim to schedule your maintenance tasks in a way that minimizes disruption and maximizes efficiency for your facility.

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Allan White

Maritime Technical Manager at Targe Towing Ltd
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Utilising condition based monitoring (CBM) will allow you to schedule maintenance at a suitable time before breakdown occurs. This is the main reason for the creation of CBM. With respect to maintenance schedules set out by the manufacturer it is vital that these are adhered to. Quite simply put, if operations dictate a timetable then maintenance should be scheduled early enough to avoid going past due. If equipment therefore requires to be "maintained" earlier then that is what is required.

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5 Communicate your maintenance plan

After you have scheduled your maintenance tasks, you need to communicate your maintenance plan, which is the document that summarizes and explains your maintenance goals, needs, tasks, and schedule. You can use various formats to communicate your maintenance plan, such as reports, presentations, or dashboards. You should also consider the stakeholders and audiences of your maintenance plan, such as the management, the staff, the suppliers, or the customers. You should aim to communicate your maintenance plan in a clear, concise, and consistent manner that ensures alignment and engagement for your facility.

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6 Monitor and evaluate your maintenance performance

Once you have communicated your maintenance plan, you need to monitor and evaluate your maintenance performance, which are the measures and feedback that you will collect and analyze to assess your maintenance results and outcomes. You can use various sources to monitor and evaluate your maintenance performance, such as data, reports, surveys, or reviews. You should also consider the indicators and benchmarks of your maintenance performance, such as the availability, the reliability, the quality, or the safety of your facility. You should aim to monitor and evaluate your maintenance performance in a regular, systematic, and objective way that enables improvement and learning for your facility.

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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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Roger Borycki

Helping Companies Improve | Reliability | Operations | Maintenance | Engineering
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Because the critical driver for any production facility is output, the amount of downtime for a maintenance plan will always be a primary consideration. Take into account what tasks/setup can be done while the equipment is operational and do them while the equipment is running, or while the equipment is in the process of being shut down. Also look at the startup of the process, will all equipment start at once or will it be staged? Are there opportunities to look at the critical path and use it to your advantage? Understand that components have individual life cycles. Sometimes you will have to optimize the overall process, by suboptimizing the life of a component.

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What are the best practices for scheduling maintenance tasks in a manufacturing facility?

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3

4

5

6

7

1 Identify your maintenance goals

2 Assess your maintenance needs

3 Prioritize your maintenance tasks

4 Schedule your maintenance tasks

5 Communicate your maintenance plan

6 Monitor and evaluate your maintenance performance

7 Here’s what else to consider

Critical Thinking

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What are the best practices for scheduling maintenance tasks in a manufacturing facility?

1

2

3

4

5

6

7

1 Identify your maintenance goals

2 Assess your maintenance needs

3 Prioritize your maintenance tasks

4 Schedule your maintenance tasks

5 Communicate your maintenance plan

6 Monitor and evaluate your maintenance performance

7 Here’s what else to consider

Critical Thinking

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