Course 901: Maintenance Organization

Covers the basic types of maintenance organizations. Discusses cost-saving concepts of using work order systems. Explains how to develop and use information sources to implement maintenance management. Shows how to apply work standards and planning procedures to simplify a supervisor’s job. Introduces the use of computers for first-line supervisors.

Lesson 1: Types of Maintenance Organization

Topics:

Maintenance management; Objectives and priorities; Performing effectively Overcoming maintenance problems; Types of maintenance organizations; Comparing organizations; Who controls maintenance?; Span of control; Using organizational charts; Department changes

Objectives:

• Describe the functions of the first-line supervisor, the middle-level supervisor, and the top-level supervisor.
• List some of the common problems that lead to difficulties in operating a maintenance department.
• Outline the differences among functional organizations, area organizations, and the centrally controlled maintenance organization.
• Explain the chain of command of a company using its organizational chart.
• Identify the elements that make employees resistant to reorganization, and what can be done to counter this resistance.

Lesson 2: Maintenance Planning and Operations

Topics:

Maintenance management system; Defining the workload; Maintenance vocabulary

Objectives:

• Describe the way the first-line supervisor’s position fits into the overall maintenance system.
• List five types of written orders that can be used for assigning work.
• Classify different kinds of repairs and list them in proper order of importance.
• List the duties of the maintenance planner and the maintenance engineer as they relate to the duties of the first-line supervisor.
• Define standard terms of the maintenance supervisor’s vocabulary.

Lesson 3: Work Order Systems

Topics:

Work orders; Controlling costs with work standards; Other system components; When to use the EWO or MWO; MWO format; Reporting resource use; Standing work orders; Equipment master file; Planner’s use of the MWO; Function of the EWO; PM work orders; Manual work orders; Master schedule as a work order

Objectives:

• Describe the use of the maintenance work order.
• Explain the importance of job priorities.
• Identify two basic types of work standards.
• Distinguish between the uses of the engineering work order and the maintenance work order.
• Describe the uses of the master schedule and the PM work order

Lesson 4: Using Information Sources

Topics:

The uses of maintenance information; Controlling maintenance through information; Controlling labor uses and costs; The computer-based management system; Labor control information; Reporting labor information; Controlling major jobs; Material control; Maintenance costs; Noncomputer information; Informal information; Performance information you’ve always wanted to have; Supervisors need information; Improving the information environment

Objectives:

• Explain the importance if using information sources.
• List the types of information that originate within the maintenance department and from other sources.
• List the elements that must be considered when developing a computer-based information system.
• Describe the uses of labor control information.
• Calculate manhour performances indexes.

Lesson 5: Controlling Backlog through Planning

Topics:

Why is maintenance planning important?; Planning as a maintenance management tool; Planning concepts; Coordinating the plan; Detailed maintenance planning procedures; Plan for craft skills; Special planning considerations; Sources of planned work; Effect of planning on manpower use

Objectives:

• Explain the role planning plays in reducing downtime costs and improving manpower use.
• List the five steps of the decision-making process.
• Define goals, objectives, policies, procedures, and programs in the context of maintenance planning.
• Describe the role of the maintenance planner.
• List six areas in which planning enhances labor use.

Lesson 6: Applying Work Standards

Topics:

Why use standards?; Time standards; How are time standards used?; Standards help to reduce costs; Using engineered performance standards; The spreadsheet; Controlling the backlog; Assigning priorities; Scheduling work; Craft use and backlog; Analyzing backlog data

Objectives:

• Explain why standards are used.
• Describe quality and quantity standards and their uses.
• List five conditions a maintenance department must meet in order for standards to be workable.
• Describe how different types of standards are developed.
• State how the backlog can be analyzed to evaluate the makeup of the workforce.

Lesson 7: Managing Maintenance by Computer

Topics:

The computer’s function; Information sources; Computer files; Processing data; Sources of data-processing support; Package programs; Accessing and inputting information; Computerizing essential maintenance information; Making use of computer information

Objectives:

• Describe the function of the computer in maintenance information management.
• List the types of information that should be stored in a computer.
• List types of data processing support available to maintenance departments.
• Use basic computer terminology.