Series 900: Maintenance Management
Course 904: 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:
Categories of workloads; Techniques for computing workloads; Distributing the workload; Effects of absenteeism, overtime
Learning 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.
- Explain the effects of absenteeism and overtime on the workload.
Lesson 2 - Controlling Labor
Topics:
Control of maintenance labor; Handling absenteeism; Overtime vs bringing on extra people; Vacation schedules; Productivity
Learning Objectives:
- Identify the seven categories of maintenance labor
- 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.
- 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:
Inventory control; Reordering stock; Rebuilt and fabricated parts; Calculating economical order quantities; Reorder points; Two-bin system
Learning 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; Rebuilds and overhauls; Shop, work area layout; Shop care and cleanup
Learning 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; Improved productivity; Budgeting; Types of budgets; Key equipment in the budget
Learning Objectives:
- Describe the effect increased productivity has on maintenance costs.
- List the uses of a budget.
- Describe zero-based budgeting.
- Describe performance 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.
