The adoption of marine ERP systems has revolutionized maintenance management in the marine industry, offering opportunities and challenges. Effective computerisation requires a thorough understanding of the core components of maintenance management, which apply to diverse maintenance tasks, including routine, preventive, corrective, shutdown, and emergency maintenance. Below, we delve into the essential aspects of computerised planning and scheduling for marine operations.
Key Components of Maintenance Management
1. Work Requests:
A work request communicates specific maintenance needs, detailing critical information such as the equipment number, job number, required work, approvals, and priority levels. Proper documentation ensures clarity for the maintenance team.
2. Work Orders:
Work orders outline the scope and specifics of maintenance tasks. They include equipment details, job numbers, work descriptions, and resources needed, such as materials, tools, and personnel. These documents form the foundation for planning, scheduling, and creating maintenance histories, streamlining future analyses.
3. Prioritisation:
Efficient prioritisation determines the urgency and criticality of maintenance tasks. By assessing operational impact, safety concerns, regulatory compliance, and resource availability, maintenance teams can address high-priority jobs effectively, optimising resource utilisation.
4. Work Planning:
Planning involves addressing the "5 Ws and 1 H":
- Why is the work needed?
- What needs to be done?
- Who will perform the task?
- Where will it take place?
- When will it occur?
- How will it be accomplished?
This structured approach identifies resources, risks, and steps, minimising downtime and reducing costs.
5. Scheduling:
Scheduling aligns resources with tasks to ensure maintenance occurs efficiently. Plans are typically organised daily, weekly, monthly, or annually, focusing on minimising disruptions while meeting deadlines.
Enhancing Marine Maintenance with Computerised Systems
Organised Databases:
Computerised systems maintain a centralised database, incorporating cost assignments, equipment identification, crew lists, and spare parts catalogues. These databases enable informed decision-making and efficient resource allocation.
Cost Assignments:
Clear cost allocation procedures help cost centres or departments track expenses, aligning with established accounting practices.
Equipment Identification:
Unique identification codes simplify tracking and maintaining equipment. Grouping similar equipment under categories enhances efficiency while preserving detail.
Crew Management:
Crew lists detailing trades, roles, and availability support efficient task assignments and resource tracking.
Benefits of Computerisation
Improved Maintenance Planning:
Computerised systems offer tools for backlog management, resource allocation, and cost tracking, improving operational efficiency by up to 50%.Enhanced Reporting and Analysis:
Comprehensive reports provide insights into work orders, inventory usage, and equipment performance, supporting continuous improvement.Streamlined Workflows:
Integration of work orders, prioritisation, and scheduling ensures seamless communication and execution.
Implementation Steps for a Computerised Maintenance Management Program
1. Defining the Program:
Identify needs, costs, and system requirements. Then, decide whether to develop the software in-house or purchase an off-the-shelf package.
2. Organising the Implementation Team:
Form an interdisciplinary team with maintenance, data processing, and accounting expertise to oversee system definition and deployment.
3. Orientation and Training:
Educate personnel on using the system, from creating work requests to retrieving reports. Effective training ensures system adoption and utilisation.
4. Role Allocation:
Assign data entry, file maintenance, and report generation responsibilities to ensure smooth operations.
Features of an Effective Computerised Maintenance Management System (CMMS)
1. Online Inquiry:
Real-time access to work orders, materials, and equipment data reduces paperwork and enhances productivity.
2. Custom Report Generation:
Generate tailored reports for data-driven decisions, including equipment history, downtime, inventory valuation, and failure analysis.
3. Performance Monitoring:
Track performance against benchmarks using concise, actionable reports, including schedule compliance and backlog summaries.
The Importance of a Formal Work Order System
A work order system standardises maintenance operations, ensuring tasks are properly planned, prioritised, and tracked. This system:
- Facilitates resource allocation.
- Tracks performance metrics.
- Enhances communication between departments.
Implementing a Priority System: The RIME Approach
The Ranking Index for Maintenance Expenditures (RIME) system assigns priority levels based on equipment criticality and task importance. This structured approach minimises biases and aligns maintenance activities with operational priorities.
Advanced Features of Computerised Systems
Inventory Management:
A CMMS ensures spare parts availability by tracking inventory status, vendor information, and reorder requirements.
Equipment Monitoring:
Maintain detailed equipment histories, monitor performance trends, and optimise preventive maintenance schedules.
Performance Analysis:
Use advanced analytics to identify inefficiencies, evaluate costs, and improve maintenance strategies.
The Path Forward: Continuous Improvement
Planning and scheduling are dynamic processes. Regular audits of work orders, coupled with feedback from completed tasks, refine maintenance strategies, reducing delays and optimising outcomes.
FAQs on Computerised Planning and Scheduling in Marine Maintenance
1. What is the primary benefit of computerising maintenance management in the marine industry?
Computerisation enhances efficiency by centralising data, streamlining planning, scheduling, and reporting processes, and reducing downtime and costs.
2. How does prioritisation improve maintenance operations?
Prioritisation ensures critical tasks are completed first, optimising resource allocation and preventing costly operational disruptions.
3. What features should a good CMMS include?
A robust CMMS should offer real-time data access, custom reporting capabilities, performance tracking, and seamless integration of inventory and work orders.
4. How can equipment identification systems benefit maintenance management?
Unique equipment identification simplifies tracking, supports preventive maintenance, and improves resource allocation.
5. Why is a formal work order system essential?
A work order system standardises processes, tracks performance, and ensures accountability, leading to better decision-making and resource management.
Disclaimer:
Out
of Box Maritime Thinker © by Narenta Gestio Consilium Group 2022 and Aleksandar
Pudar assumes no responsibility or liability for any errors or omissions in the
content of this paper. The information in this paper is provided on an "as
is" basis with no guarantees of completeness, accuracy, usefulness, or
timeliness or of the results obtained from using this information. The ideas
and strategies should never be used without first assessing your company's
situation or system or consulting a consultancy professional. The content of
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