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September 26, 2011

Opportunity Maintenance- A point of view: Part 2

In continuation to what we were talking on Opportunity Management (OM) in Part 1, following picture graphically shows how the OM is planned:



In the illustrated picture there is a breakdown of a machine which is expected to take 4 days to restore it back. This has resulted in the stoppage of the production area. The primary focus would be on to restore the machine as quickly as possible and restore the machine back to its original condition.
However there are work orders which are falling within those 4 days + 3weeks window of time which needs to be executed and subsequently these will also stop the process. Other work orders which does not necessitate production stoppages and falling in this window can also be clubbed maximize the utilization of OM window.

Challenges for opportunity Maintenance
Following are challenges envisaged for opportunity maintenance,
1. No clear idea on how long the machines under breakdown will be restored - Many times it takes considerable time to identify the root cause of the issue hence no accurate duration of machine down time can be predicated. This will impact others getting the benefit of Opportunity window.
2. The software does not support pulling the maintenance work orders based on Opportunity selection criteria like duration, location and priority wise
3. Unavailability of Resource - since the focus will be on breakdown rather than planned maintenance in such situations.
4. Non availability of spares
5. Non Availability of external service / delay in getting internal approvals for external service
6. Sometimes the machine which was under breakdown might be restored earlier than anticipated creating pressure situation on planned maintenance works.

Conclusion and Recommendations
While this is an opportunity to carry out planned works during such window , but it requires enormous coordination and accurate planning and more important it requires Management support to make use of opportunity windows.

September 17, 2011

Opportunity Maintenance- A point of view: Part 1

By Gopal Krishna

Opportunity Maintenance (OM) is the term we are using to describe an opportunity window of maintenance for the machines by virtue of breakdown with another machine(s). In this article let us discuss about the event for opportunity window, how maintenance tasks can be identified and execute within this time frame and finally look at the challenges posed for doing opportunity maintenance.

Detailed Analysis
For an opportunity maintenance window to occur there must have been failure / unscheduled stoppage of a machine which has resulted in partial or full stoppage of a process area.


002a.pngHow fast and accurate your planner can pull the list of maintenance work lists for the opportunity window? This is very crucial step in maximizing the utilization of this window? Following are the list of activities envisaged for such an opportunity
• Identify the duration of the breakdown; alternatively plan for the opportunity time
• Pull list of maintenance work(s) meeting the opportunity time window
• Prioritize the work lists
• Determine the no of hours required; find out the available capacity
• Material availability check; plan for material issue from stores
• Decide   if required to go for external service  in case the demand capacity is more
• This may involve pre scheduling some work orders planned in within near future time (1-2 weeks)
• Execute and complete the work / report the work orders completed.

Scheduling Principle for Opportunity Maintenance
The core objective of the opportunity maintenance is to complete as much maintenance work as possible within the opportunity window, however the principal theory behind OM would be to execute only such works which are falling in the OM window which would otherwise require scheduled stoppage of the specific area.  One would need to be experienced enough to decide on how much of future maintenance work can be bring forward in time?

In our next blog, we will discuss, with graphical representation, how OM is planned, challenges faced in OM and our recommendations.

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