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CASE STUDY EXAMPLE

CASE STUDY EXAMPLE. Work Process Flow Charts. WORK IDENTIFICATION / WORK ORDER PROCESSING. Identify Work. Operator Performs Maintenance. Investigate Problem. Determine Urgency. Can Operator Perform Work?. Everyone. Operator. Identifier. Shift Supervisor. Shift Supervisor.

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CASE STUDY EXAMPLE

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  1. CASE STUDY EXAMPLE Work Process Flow Charts

  2. WORK IDENTIFICATION / WORK ORDER PROCESSING Identify Work Operator Performs Maintenance Investigate Problem Determine Urgency Can Operator Perform Work? Everyone Operator Identifier Shift Supervisor Shift Supervisor • Everyone is responsible to ID work (early) • Early work ID is safer and less costly • Operator performs Maintenance if possible • If not, go to next step • Gather problem information then contact supervisor • What is the problem/opportunity? • Where is it (asset location/identifier)? • When does it occur (related process operation, etc.)? • How much is it occurring (minor vibration, large rate of drip, leak, break, etc.)? • How often (all the time, sometimes, rarely)? • Note: If it is suspected an Emergency condition, go directly to next step • Shift supervisor responsible for declaring Emergency/Urgent status • Troubleshoot with team • Determine if work is required • Operator Performs Maintenance • If not, record all relevant information for quality notification input Enter Notification Review Notification Determine if it will be worked under blanket MO Determine How It Will Be Worked Hang Work ID Tag Shift Supervisor / Designee Asset Coordinator Asset Coordinator Asset Coordinator Maintenance Coordinator/Designee • SAP • EZ-notification • Notification complete and accurate? • Work request needed? • If not, send back to Identifier • Reference Blanket Order Policy (EBB) • Routine? • Capital work? • TAR? • If not Routine, give feedback to Identifier • Hang ID Tag as close to the problem area as possible

  3. ROUTINE MAINTENANCE WORK PLANNING PROCESS Field Scope Job Job Note Request Plan The Job Determine Who Will Perform Job Notification in SAP Minimum 2-3 days prior to allow for detailed planning. Planner/Supervisor Planner/Supervisor/UME Planner Planner/Supervisor Planner • Planner visits work site to assemble information for plan. Materials, tools, equipment, and craft resources needed • Supervisors/Job Reps may also be asked to review job • Safety requirements must be observed • Planner works with Supervisor to determine job note need • The Planner contacts the Unit Maintenance Engineer to create job note if needed. • Non-core work is tasked to contractor • The Planner and Supervisor determine if contractors will be needed to perform the work • Search SAP database to find existing job template if available. Plan as new if not available • The Planner copies the template into the new maintenance order • The maintenance order can be updated with additional details, job steps, etc. • Update status to planner group 1 • Planner reviews new approved notifications in SAP. • Assures job description is adequate. • Create M.O. with planner group 0 Craft Assignments Entered Into SAP Materials, Tools, Equipment Into SAP QA/QC Requirements Identified Event Based Budget Review Detailed Job Package Assembled Permit is Initiated Planner/Maint. Supv/Job Rep Planner/Unit Inspector Planner Planner Planner Planner • The Planner enters detailed tasks into SAP with correct work centers • Work centers are used in SAP to determine what crafts will work each task • Multiple tasks are entered for operators as well as crafts • The Planner enters stock and non-stock materials into the plan • Procurement Coordinators are asked to help procure materials when needed • Planner will use the VAM (Vendor Agreement Management) tool when buying non-stock items • Unit inspectors are notified when work will be performed • The Planner will include steps for inspection and quality control in the estimate • The Planner will determine if the work is budgeted before releasing the order for work. • If the work is Not in the budget, a variance will need to be created and approved. • Release material requisitions. • Minimum Job Plan Requirements • - Complete SAP printed M.O. • - Primary & secondary crafts • - Labor estimates • - Description of job steps • - Status of materials & locations • - QA/QC requirements • - Repair specifications • - Location of work • Maintain ready to schedule file • Update status to planner • group 2 • The Planner will initiate permits for all tasks on the order that require one • The Planner will contact the correct Maint. Supv. / Job Rep. to begin the risk assessment • Appropriate level of risk assessment and permit creation occurs

  4. ROUTINE MAINTENANCE WORK - DAILY SCHEDULING PROCESS Update Current Day’s Schedule Preparation for Unit Daily Scheduling Meeting Conduct Unit Daily Scheduling Meeting Permit Creation Planner, Supervisor, Asset Coordinator Operations / Maint, Supervisor / Job Rep. Planner Scheduler • Planner reviews current day schedule with completed work and work that will carry over to the next day • Updates are made in the current tools • Scheduler, Maintenance Supervisor, and Planner provide the Asset Coord. with MO status information in preparation for the Unit Daily Scheduling Meeting • Mandatory attendees: Asset Coordinator (Team Leader), Maintenance Supervisor, Planner, Maintenance Coordinator, Operations Supervisor • Attendees as appropriate: Unit Engineer, Inspections, Capital Project Reps, Job Rep’s etc. • Operations and Maintenance Supv./Job Rep. verify permit readiness by reviewing risk assessment, initiated ATW and associated permits Address Schedule Deviations Address Resource Issues Run Final Schedule And Update Backlog Notification of Schedule Availability Planner Scheduler, Planner Scheduler Scheduler • Planner contacts scheduler to make necessary changes. For break-in-work, EBB and financial controls requirements, resource availability (materials, manpower, and rentals), this must be fulfilled prior to adding jobs to the daily schedule • Scheduler reruns schedule for deviations (additions / deletions) • Planner contacts Maintenance Supervisor to support manpower requirements • Scheduler runs final schedule for approved work • The Planner updates the backlog per final resource decision • Scheduler sends email notice of schedule availability to site teams

  5. WEEKLY WORK SCHEDULING PROCESS Ready to Work Backlog Weekly Scheduling Meeting Scheduler Creates Schedule Resource Validation & Update Site Wide Scheduling Meeting Planner, Maint. Supv, Main.t Coord, Shift Supv, Asset Coord. Scheduler, Planner, Asset Coordinator Planning Scheduling Supt. /Asset Coords, TAR and Routine Planning & Scheduling Leads, Shift Director, Schedulers Planner Scheduler • Planner sends a copy of the RTW backlog to the unit team members • Scheduler downloads coded Maint. Orders from SAP into P3e draft schedule • Scheduler incorporates TAR, Tank TAR, infrastructure, and capital projects schedules into the P3e draft schedule • Select jobs for weekly schedule that meet the unit requirements for safe optimal operation • Considerations for selection: • LOTO • Priority • Equip. Availability • Carry over work • Critical trips & alarms • PM’s • Budget • Backlog • Updated RIME priorities • Planner codes scheduled Maint. Orders in SAP by 2:30 pm • Scheduler levels resources • noting any conflicts because • of resource or CoW issues • Scheduler contacts unit planner where resource restrictions are found • Planner contacts asset coordinator for review • Asset Coordinator prepares to discuss issues around resource allocation • Planning Superintendent facilitates a high level review to gain consensus on what will be worked on at a high level • Attendees commit to schedules Finalize Schedule Scheduler • Scheduler makes changes to schedule resulting from the weekly meeting • Scheduler makes schedule available on the website no later than Thursday at 4:00 pm

  6. ROUTINE MAINTENANCE WORK EXECUTION AND ACCEPTANCE PROCESS Received from the Planning And Scheduling Process Day before the job starts Start of the Day Job Start-up Job Start-up (con’t) Operator / Maint. Coord. Maint. Supv. / Job Rep. / Ops. Supv Operator / Craftsman / Job Rep Operator / Craftsman / Job Rep. • Job Packages • Daily Schedules • Hazard Assessment (training in progress) • Operator verifies that the area is clean and ready for maintenance • Maintenance coordinator communicates with nearby units as needed • Maintenance coordinator verifies that critical jobs are ready to be worked • Night Operations finalizes equipment preparation for maintenance • Maint. Supv. or Job Rep. reviews job package for completeness • Maint. Supv. / Job Rep holds maintenance safety meeting/contractor lineup • Ops. Shift Supv holds operations pre-shift meeting • Ops Shift Supv approves any hot work or confined space entry permits • All personnel entering unit must sign in at the control room • Operator, craftsmen and Job Rep. walk the job on new jobs, verifying that isolation, LOTO, etc have been completed • Verify equipment is energy-free • Operator, contractor crew rep and job rep (contractor work) sign the ATW • Work Crew Rep or job rep (contractor work) or responsible operator review the Permit Pack and conducts pre-job safety review with everyone in the work crew. • Work Crew Declaration signed by all • New work crew member needs the pre-job safety review prior to work and needs to sign the ATW • Operator and contractor crew representative walk the job on continuation work each shift to revalidate permits Job Execution Job Completion Job Completion (con’t) Post-Job Completion Post-Job Completion (con’t) Craftsman / Operator Craftsman / Operator Craftsman / Operator Craftsman / Maint. Supv. / Job Rep. / Asset Coordinator Craftsmen / Maint. Supv. / Job Rep. • Work is performed by craftsmen/contractors within bounds of work scope and permits • If job scope increases, permit is revoked and JCO process is initiated. New permit process needs to be initiated • Maintenance Supervisor/ Job Rep follow up in the field. • QA/QC work included as part of the job • Job site clean-up by maintenance • Test equipment if possible • Operator and craftsmen walk the completed job • Isolation controls can now be removed. • Operator and craftsman sign off on ATW and QA/QC (if applicable) • Craftsman and Operator sign off on the MO • Equipment is prepared by Operations for return to service • If more work is required, a new notification is created • Craftsman removes Work ID tag if equipment tests satisfactorily (Future state) • Craftsmen update Maint. Supervisor / Job Rep. on job • Work history documented on the MO sign off sheet. (To be used for work Documentation and Analysis process) • Work package given to Maint. Supv. / Job Rep. • Asset Coordinator informs shift operations that equipment has been returned to service

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