Series 900: Maintenance Management
Course 903: Controlling Maintenance Resources
Covers methods of using maintenance resources for greatest efficiency, and tells how to implement the techniques effectively. Explains what workload is and how to measure it. Provides a thorough investigation into the control of labor, parts, and materials—both in the field and in the shop. Examines the budget process and how to control costs through budgeting.
Lesson 1: Measuring Workload
Topics:
What is the workload?; Categories of workloads; Techniques for computing workloads; Distributing the workload; Effects of absenteeism, overtime on workloads; Workloads vs. backlog levels
Objectives:
- Define workload and explain its importance in control of maintenance work.
- List the seven workload categories.
- Compute workload measurements for each of the seven categories.
- Explain how the workload should be distributed.
- Describe the effects of absenteeism and overtime on the workload.
Lesson 2: Controlling Labor
Topics:
Maintenance labor control; Overall control of maintenance labor; Responsibility of control; Observe and react; Handling absenteeism; Overtime vs. bringing on extra people; Planning vacation schedules; Processing vacation requests; Productivity and the supervisor
Objectives:
- Identify the seven categories of maintenance labor discussed.
- Describe the most effective means of controlling each of the seven categories of maintenance labor.
- Explain the effect a well-executed PM program has on other maintenance work.
- State the leading factors contributing to absenteeism.
- Determine the breakeven point between overtime and hiring additional workers
- Schedule vacation periods so that production still proceeds smoothly.
Lesson 3: Controlling Parts and Materials
Topics:
Material control; Controlling inventory; Who should control the inventory?; Administrative control of maintenance work; Duties of the material controller; Inventory control systems; Operating a manual control system; Reordering stock; Rebuilt and fabricated parts; Calculating order quantities and reorder points; The two-bin system
Objectives:
- Explain the importance of effective material control to maintenance work.
- Describe the duties of the material controller.
- Describe the operation of a typical manual inventory control system.
- Calculate economic order quantities and reorder points.
- Operate a two-bin inventory control system.
Lesson 4: Managing Shop Operations
Topics:
Shop control; Liaison with field work; Engineering project support; Shop rebuilds and overhauls; The shop workload; Mobile equipment maintenance; Material support; Parts and component rebuilding; Performance in the shop; Shop location, layout, and configuration; Work area considerations; Shop care and cleanup; Central shop vs. area shops
Objectives:
- Describe the differences in labor control between shop and field work.
- Describe the role played by a shop that supports a field crew.
- List the steps required to rebuild parts.
- Explain how shop location, layout, and configuration affect work.
- List the advantages and disadvantages of central and area shops.
Lesson 5: Controlling Costs through Budgeting
Topics:
Cutting maintenance costs; Effect of improved productivity; The structure of maintenance costs; Budgeting maintenance costs; Types of budgets used by maintenance; Key equipment in the budget; Maintenance cost reduction strategy; All work must be approved
Objectives:
- Describe the effect increased productivity has on maintenance costs.
- List the uses of a budget.
- Describe zero-based budgeting.
- Describe the factored budgeting.
- List the eight steps in formulating equipment repair projections.
- Explain the reason why all maintenance work should be approved before it is performed.
