280998LNOXN007LRJL-P1PoS1CONFIDENTIALAnImprovedPlanningandSchedulingProcessforPlant1MaintenanceThisreportissolelyfortheuseofclientpersonnel.Nopartofitmaybecirculated,quotedorreproducedfordistributionoutsidetheclientorganisationwithoutpriorwrittenapprovalfromMcKinsey&CompanyThismaterialwasusedbyMcKinsey&Companyduringanoralpresentation;itisnotacompleterecordofthediscussionExampleCompanyExampleImplementationManualSeptember1998280998LNOXN007LRJL-P1PoS2CONTEXTANDPURPOSEOFTHISDOCUMENT•Thisdocumentisbasedonengagementworkataprocessindustryclientin1997-8•Theclienthadcompletedphases1-4ofaTOPprogrammeinoneoftheirplantsandhadsuccessfullyachievedthetargets•Manyoftheirkeyrecommendationsencompassedfundamentalchangestokeypartsofthemaintenanceprocessincluding–Equipmentstrategies–Planningandscheduling–Measuringperformance–Systemscopeandusage–Rootcauseproblemsolving•However,thebeginningoftheimplementationphase,theclientwasstrugglingtotranslatetheTOPideasintoworkablereality;inparticular,theyexperienceddifficultywiththeprocesschangesandsupportingtoolsrequired•TheMcKinseyteamthereforecontinuedtoworkcloselywiththeclienttoproducedclient-owned“implementationmanuals”forthekeypartsofthemaintenanceprocesswhichrequiredimprovement.Thesemanualsservedseveralpurposes–Documentedagreementtoa‘process’viewofmaintenance(PDCA),definitionsandpolicies–Workingexamplesofprocedures,checklists,decisionrules,KPIs,evenmeetingagendas,whichwerethefundamentaltoolsoftheimprovedprocess–Avehicleforanimplementationplanwithclarityonkeydatesandresponsibilities•Thisdocumentis,insanitizedform,oneofthe“implementationmanuals”fromthatprocess.Teamsareencouragedtouseitasabasisfordiscussionor‘strawman’forasimilarexercisewithclientsstrugglingtoimplementmaintenanceimprovement.Duetothespecialisednatureofmostfacilities’maintenanceoperations,andtheneedtobuildbuy-inbottom-upincludingthemanyconstituentsinvolvedinmaintenance(operators,maintainers,engineers,etc.),itisclearlynotrecommendedas“theanswer”toclientsmaintenanceprocessissuessinceitishighlyunlikelythat‘onesizefitsall’•Thisdocumentisonemoduleofanoverallcollectionofmaintenanceimplementationsupportmaterials.Forfurtherinformation,contact:JohnLydon-UK/LNFrancoisRozon-UK/JHAndrewStamp-AU/SYStuFlavin-AT280998LNOXN007LRJL-P1PoS3Theimprovedplanningandschedulingprocessusesseveralkeyterms,possiblyindifferentwaystotheirtraditionaldefinitions.ItisimportanttounderstandtheiruseinthisdocumentPLANNINGANDSCHEDULING:KEYTERMSEquipmentstrategiesTasks/jobsPlanningSchedulingTasks/jobsareeithergeneratedbytheequipmentstrategies(e.g.aPMevery4weeks),orbyaworkrequest(e.g.followingabreakdown,tocorrectafaultorperformmodification)Planningistheprocesswherejobscope,parts,tools,estimatedresources/timerequired,aredefinedandprework(e.g.orderingparts)iscompletedItisNOTtheprocesswherethejobisassignedatimewhenitwilltakeplaceAlljobs,apartfromemergencytasks,shouldbeplannedSchedulingiswhereplannedjobsareassignedtimeswhentheywilltakeplaceThelistofjobswithtimesandresourcesattachediscalledthe‘schedule’JobsshouldbeplannedbeforetheycanbescheduledPlanningandschedulingaredifferentactivitiesperformedatdifferenttimesThewayequipmentismaintained–e.g:•Runtofailure•Preventativemaintenanceevery4weeks•Conditionmonitoring,etc,includingdetailsof:–HowoftenPMstakeplace–Whichpartsarechanged–Etc280998LNOXN007...
