Maintenance work: Part 2


By Donald H. Decker, PE, Principal

The Hayo Consultants
( )

This is the second installment in a three-part article about Maintenance work. We are centering on the “Make Ready, Do, Put Away” activities of your maintenance crew.

Quite often maintenance productivity is associated with the motivation level of our maintenance and technical personnel. There is more to maintenance productivity than the people actually performing the “hands-on” work.

From the moment the maintenance and technical people enter the workplace to the moment they leave, managers are concerned about productivity or getting the work done (the Do).

Just how can we measure the productivity of our crews in that time span?

There are many ”traditional” methods of measuring work performance.


Analytical estimating
Estimate the amount of time it takes to do each planned maintenance work order. Compare the estimates against the actual times when jobs are finished for the week/month. The growth or shrinkage of the work order backlog in terms of crew weeks can be tracked and management adjustments made accordingly.


Historical work measurement
Historical time data is gathered for job elements. Statistical analyses are run on these completed jobs to get averages.


Engineered standards
Pre-determined standards are developed for each element of each job. These are used to estimate work times for each element and the times for all elements on a given job summed to get the total job times.


Time and motion standards
This system uses the same approach as engineered standards, but the elements are documented for the given facility in which they are installed.


Work sampling
Crews are sampled against pre-determined categories of work activities, using an even smaller list than is outlined in installment No. 1 of this article. Routes are selected, samplers are trained, random sample times for conducting the routes are distributed, samples are taken, and data are gathered and analyzed.


The latest and most efficient way to determine your productivity is one that might be termed “non-traditional," even though it incorporates many traditional elements.


Overall crew/facility productivity
The most efficient way to gauge overall maintenance crew/facility productivity is to use a time-tested empirical chart. Placing your organization on the chart will yield very quickly how you stand versus where you can be. Having an organized maintenance planning and scheduling effort is the key to having the Do optimized.


The productivity of your maintenance and technical personnel depends greatly upon the type of systems and policies that management has applied to the maintenance operations. The types of policies and systems that are employed will be highlighted in the next installment.


The third and final installment explores the most efficient way to measure crew work, the Do!

Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
November 2018
2018 Product of the Year finalists, mild steel welding: finding the right filler, and new technique joins aluminum to steel.
October 2018
Tools vs. sensors, functional safety, compressor rental, an operational network of maintenance and safety
September 2018
2018 Engineering Leaders under 40, Women in Engineering, Six ways to reduce waste in manufacturing, and Four robot implementation challenges.
October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
Summer 2018
Microgrids and universities, Steam traps and energy efficiency, Finding help with energy projects
October 2018
Complex upgrades for system integrators; Process control safety and compliance
November 2018
Analytics quantify processes, Fieldbus networking and IIoT, Choosing the right accelerometer

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
click me