MAINTENANCE SCHEDULING

“How to Implementation: Service Schedule, Backlog & GOH

to Improve Physical Availability”

Presented By:
Balikpapan, 25 November 2016 Nurtua Anita Manalu – IPPS0740

Maintenance Scheduling
1 25 November 2016
 DEFENISI & CAKUPAN
MAINTENANCE SCHEDULING
A short definition of maintenance planning and scheduling:
Planning decides what, how and time estimate for a
job. Scheduling decides when and who will do the job. Planning
of a job should be done before scheduling a job. There are two
main types of maintenance: preventative maintenance (routine)
& corrective maintenance.

Preventative Maintenance Scheduling:

*Service Periodic Maintenance
*Daily or PM Check & Backlog
*Overhaul Program (GOH)
*Exchange & Remand Component
Corrective Maintenance Scheduling:
*Un-schedule Program (Accident, Redo Job)

Maintenance Scheduling
2 25 November 2016
 SERVICE PERIODIC MAINTENANCE

Service Periodic Maintenance, start from arrival unit:

* Field Guidance/ Commissioning
* Service 100 HM
* Service 500 HM
* Service 1000 HM

Service Periodic Maintenance for unit out of warranty:

* Service Interval 500 HM
* Service Interval 1000 HM
* Service Interval 2000 HM
* Service Interval 4000 HM
* Service Interval 6000 HM

Maintenance Scheduling
3 25 November 2016
 PM CHEK & BACKLOG MANAGEMENT

Backlog
Suatu kegiatan preventive maintenance
dengan melakukan identifikasi dini gejala-
gejala kerusakan, membuat scheduling
perbaikan yang tepat agar tidak
mengganggu kegiatan operasi alat.
Daily Inspection or PM Check
Suatu kegiatan preventive maintenance
dengan melakukan pengecekan unit
(add oil, add radiator, greasing dump
body, check propeller shaft & steering,
make part recommendation)

Kerusakan ?

Tidak berbahaya (safety)

Tidak menimbulkan kerusakan
lebih parah

Maintenance Scheduling
4 25 November 2016
 MANFAAT BACKLOG MANAGEMENT

UNSCHEDULED SCHEDULED BENEFIT

No Preparation : Good Preparation : Reduce
• Part • Part
Frekuensi
• Exchange Comp • Exchange Comp
B Down
• Man Power • Man Power E
• Tools
A • Tools
F G
• Facility C • Facility
F O CUSTOMER
K SATISFACTION
E A
L RAISE
C Reduce Cost L PA
O
No spare time Have Spare Time T Moving
G
Bad Quality High Quality Reduce
Down Time
Short Life time Long Life Time

Maintenance Scheduling
5 25 November 2016
 FLOW PROCESS BACKLOG
Application : Prosedure Pelaksanaan Maintenance - PM Daily, Periodic Service & Backlog System - unit FMC

PM Crew Radio Operator PS Crew & Backlog PPIC Dept / Mgr Support

Pemeriksaan Laporan ke Radio

Recheck Volvo Base untuk
Unit Daily
1 catat time down & up
4

Tulis dan record

dalam PM Sheet, Record/catat di
Foto bila perlu 2 buku EMR
5

Tdk
Lengkap
Check &
Input ke program Parts
Analisa by
3 Excel Service-EMR 5a Report : Parts Dept
Spv
Olah data EMR & Backlog & kapan
Catat dgn lengkap 7
SR, Time Down & up Entry Backlog Items diperlukan
6
Time Up, Comp yg
rusak/leak/retak dgn
jelas, plus PN yg rusak

Print : Weekly Parts Dept:

Re-check Allocated Parts,
9 Backlog Items 8
by PM Spv Pelaksanaan PS NO/RS Stock. 7a
By PS Crew

Repair Backlog Planning next PS,

By backlog crew Confirmation :
PS Spv melakukan 12 back log & time
Lead time repair
Control job repair duration
13 11 Backlog, Parts, PEX
Quality Control Man Power, others 10
Field Supervisor Weekly internal meeting
Untuk review last PS Parts Dept / Parts Officer
Quality Responsible Comp Head/ CRC
dan backlog & plan next
Field Supervisor 14 backlog & PS

Maintenance Scheduling
6 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

BACKLOG MANAGEMENT

INSPECTION
& PREPARATION PLANNING EXECUTION EVALUATION
VALIDATION

Maintenance Scheduling
7 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

INSPECTION
&
VALIDATION

UPDATE
SUMMARY
KEBERSIHAN BACKLOG

• Scheduled • Update
Washing FREKUENSI VALIDASI Backlog
CHECK SHEET
• Sarana status
• Man Power
• Pengisian check sheet
• Daily Check • Job instruction Tgl, HM, Inspector,
• Sched. Service • Detail Task List P/N, Qty
• Unit Down • Format Check sheet • Cross check backlog
• Unit stand by
sebelumnya & Saat
inspection selanjutnya

Maintenance Scheduling
8 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

PREPARATION

PART TOOLS/SARANA
OVH/EXCHANGE FABRICATON

• Check Stock
• Raise SO • Check tools avail.
• Material
• Monitor Status • Check Stock • Bay workshop utk
• Kawat las
• Coordination • Raise SO/ SR/ IO pengerjaan khusus
• Welder
with Part Dept • Speed up • Check avaib.
• Procedure Fab
comp OVH Sarana/support
• Consumable
• Coordination with
CRC

Maintenance Scheduling
9 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

Weekly meeting
PLANNING coordination

DURATION
PLAN SERVICE

• List unit service • Duration PS,

• Plan date • Backlog,
• Type MAN POWER • Washing,
BACKLOG LIST • comp replace
• Duration
COMP
REPLACEMENT TOOLS/SARANA
• Alokasi man power
• List ready backlog
• Distribusi ( PIC )
• List parts status
• List comp schedule • List Tool & sarana
• ETA parts
• List PTA ready yg diperlukan
• List comp status • Update statusnya

CREATED WCS
Maintenance Scheduling
10 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

WORK CONTROL SHEET

Task list service Alokasi DURATION JOB STATUS REMARK

Man Power
Washing

Backlog

Sched Replacement
comp/parts
Additional Backlog

Tools Avaibility
Equipment support

Maintenance Scheduling
11 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

EXECUTION

PREPARATION FINAL
INSPECTION
RECEIVING
INSPECTION
• Preparation CONTROLLING
• Pre release
sebelum unit JOB DISTRIBUTION Inspection
di down kan • Check additional
(see WCS) Job diluar WCS • Control Job
sesuai WCS
• Supervisi dan • Review Progress
distribution job • Update WCS status
(target job & safety)

Maintenance Scheduling
12 25 November 2016
 EFFECTIVE BACKLOG MANAGEMENT

EVALUATION

PLAN PS PLAN BACKLOG

VS ACTIVITY
VS
ACTUAL ACTUAL

• Deviasi HM
• Deviasi Duration • List backlog finish • Buat activity plan untuk
• Hambatan/kendala • List Backlog pending perbaikannya sesuai
• Additional Backlog hasil evaluasi plan PS &
• Duration Backlog VS actual
• Hambatan/Kendala

Maintenance Scheduling
13 25 November 2016
 GENERAL OVERHAUL PROGRAM (GOH)
Standar Overhaul Component:
* Overhaul Engine
* Overhaul Transmission
* Overhaul Drop Box (Gear Box)
* Overhaul Differential (Front, Middle & Rear)
* Small Component Recondition (Compressor, Propeller
Shaft, Alternator, Starter Motor, Cylinder Dump/ Hoist,
Boom Cylinder)

Other Overhaul (base on plan):

* Overhaul Hub Kit Reduction (P1, P2, P3, P4, P5 & P6)
* Overhaul Hitch

Maintenance Scheduling
14 25 November 2016
 GENERAL OVERHAUL PROGRAM (GOH)

General overhaul di job site bisa terlaksana 100% sesuai

dengan plan, tanpa mengganggu operational, dengan
memperhatikan konsep:

Menerapkan sistem nomaden

Menggunakan part exchange & rotable component
Menerapkan sistem mixing & moving team GOH
Menentukan KPI team GOH
Membatasi scope job mekanik
Penyediaan tools & facility

Maintenance Scheduling
15 25 November 2016
 GENERAL RESPONSIBILITY OF
PLANNER
Adapun yang menjadi tanggung jawab planner adalah:
1. Menyusun daily and weekly plan untuk pekerjaan maintenance (PM, Service, Overhaul)
2. Manjalankan aktivitas health planning (daily inspections, electronic downloads,
scheduled oil sampling, lubrication and top-up oils, monitoring of application and operating
practices, monitoring equipment)
3. Membuka work orders untuk planned work
4. Membuat plan budget untuk parts, consumable, component overhaul
5. Memastikan manpower planning

Performance measurement yang digunakan untuk mengukur kinerja planning antara lain :
1. Service accuracy
2. Backlog ageing
3. Planning efficiency

Planning menjadi jembatan antara strategy dan operation, dimana planner bertanggung
jawab untuk memastikan bahwa kegiatan yang sudah di-setup oleh strategy bisa terlaksana
oleh operation. Kata lain dari planner yang mudah dipahami adalah event organizer. Target
dari planning efficiency adalah 80% downtime & cost dari maintenance activity.

Maintenance Scheduling
16 25 November 2016
 FOCUS & TARGET OF
MAINTENANCE SCHEDULING
Fokus dari planning dalam melaksanakan tugasnya adalah efisiensi, dimana dengan planning yang
berkualitas dan informasi yang akurat proses pekerjaan bisa terlaksana sesuai dengan alokasi waktu dan
biaya.

Dari model maintenance iceberg terlihat

bahwa biaya/cost yang diakibatkan dari
proses maintenance tidak hanya
berdampak pada sisi operasional
maintenance, namun dampak yang sangat
besar akan timbul pada sisi production dan
bisnis pada umumnya.
Pada praktek di lapangan sering kali terjadi
pententangan kepentingan antara pihak
maintenance dan production bahkan
safety. Oleh karena itu koordinasi lintas
fungsional dan hirarki perlu dilakukan
untuk memastikan bahwa execution
management terlaksana sesuai hasil yang
diinginkan.

Maintenance Scheduling
17 25 November 2016
 Thank you
One Team
One Target
One Result

Maintenance Scheduling
18 25 November 2016