Maintenance Manager Efficiency Certificate Program

Maintenance Management Efficiency & Process Certificate Program

Many Maintenance Operations are struggling with high emergency (unplanned) to planned work order ratio, huge backlog, lack of sufficient resources, constant work interruptions, not having parts when needed, recurring failures and much more. In these lean times, when more is expected from fewer resources, having a highly efficient maintenance program with thoughtful planning is the key to success. 

The Martin Technical Maintenance Manager Process Certificate is a program designed to help plant managers and maintenance managers to identify and test the critical components of your maintenance program, create a gap analysis, suggest practical corrective actions and provide a compass for future planning.

A 3-Day On Site Maintenance Process Training & Self-Audit Program Designed to Identify Gaps & Opportunities in Your Maintenance Program & Provide the Skills to your Management Staff for Continued Assessment and Development

This Maintenance Manager Process Certificate Program is a 3-day on-site program with follow-up report presentation designed to give plant and maintenance managers the skills to help asses their own maintenance processes in order to identify the biggest gaps and opportunities.

At the end of the program, a report will be developed outlining the critical paths for improvement and a Certificate of Maintenance Management Process and 2.4 CEUs will be awarded for all individuals that participate in the program.

benefits

Some of the benefits of this program include:

- Cost Reduction - Reduce Downtime - Reduce Maintenance Emergencies - Improve Equipment Condition/Reliability

- Improve Planning & Scheduling - Improve Inventory & Purchase Processes - Energize Maintenance Staff

 

objectives

Objectives for this program are to train facility and maintenance professinoals in how to assess their own plants and facilties for efficiencies. A successful maintenance process & efficiency audit will include:

1. Increased labor productivity
   - Reduction of overtime
   - Reduced maintenance backlog
   - Reduction in paperwork
2. Increased equipment availability
   - Minimize downtime
   - Prolong useful life of equipment
3. Reduced inventory costs
   - Minimize obsolete and excess inventory
   - Optimize inventory levels

work process

PHASE I – Customer Needs Assessment

In this phase, our Maintenance Management Professional will conduct a question and answer session via telephone with the appointed project manager at your company or organization.  Through the conversation, the Maintenance Professional will help determine the areas that might need special focus and identify what you will need to have ready upon the site visit.

PHASE II – Student Orientation

In this phase, your Maintenance Management Professional will meet with those team members who will be conducting the audit and obtaining the certificates. The objectives, work process and general planning will take place during this phase.

PHASE III – Evaluation of Processes & Training

In this phase, your Maintenance Management Professional will conduct a short course for each area of investigation. Immediately after the training, the students and your Maintenace Management Professional will put the learning into immediate action by using what was learned to assess your maintenance program and identify gaps and opportunities.

Data collected from the investigation will be recorded for inclusion in the final report.

As part of the assessment, selected plant / facility personnel will be interviewed. The average time per employee or group is 30 to 60 minutes and entire group interviews may also be necessary.

Standard Areas of Investigation:

Maintenance Work Process Flow

Work Process Flow is reviewed from start to finish. Different teams of personnel at your facility will be interviewd in order to get key feedback regarding the current process.   A shop / plant floor visit will help uncover areas that are unproductive, where delays are wasting time, and recommend improvements.

Typically maintenance organizations use 80-90% of their time on unplanned jobs and 10-20% on planned (preventive included) maintenance. The goal of this area of investigation is to help you reverse those numbers and cut down on the amount of “emergencies” your technicians deal with daily.

Preventive Maintenance Optimization

Your PM program will be reviewed, keeping critical assets in mind. Guidelines will be developed to help optimize your Preventive Maintenance frequency – either increasing it, or decreasing it (saving you money either way). A review of your Preventive Maintenance tasks will also be conducted to provide guidelines to optimize those.

Depending on your workforce and current state of affairs, this Preventive Maintenance Optimization alone can help save 20% or more in your Preventive Maintenance expenditures.

Planning and Scheduling

The Planning and Scheduling review goes hand-in-hand with your Work Process Flow review. The type of activities identified and corrected with this process are unnecessary travel, lack of parts and tools information on work orders, and lack of instructions etc. Upon completion of this phase, a typical work order (unless it is true emergency) is not dispatched until it is properly planned.

We have found that most facilities have little or no planning and scheduling processes in place. Instituting meaningful practices will turn your facility from a reactive mode to a proactive mode.

Inventory Management

Review of your inventory control program identifies obsolete and excess inventory establishing guidelines to help you turn your inventory into positive revenue.  We will also give you key solutions to better work with your suppliers to help you save even more money and gain critical work space.  Reorder points (ROP) will be reviewed with suggestions on how to help reduce money tied up in your inventory dollars.

The evaluation, when successfully followed, can help shave 10-30% off of your annual inventory dollars.

CMMS (Current or Future technology)

Facilities without Current CMMS

Facilities that are contemplating the addition of CMMS will be given a process to help determine what the correct CMMS system would be required for improved facility optimization. It will also outline the specific steps required for successful implementation, and will present important information about CMMS planning strategy - specialized to your facility.

Facilities with Current CMMS

Your current CMMS will be reviewed for it's application and optimization. This has two primary goals: 
1) to determine how to maximize the utilization of your current CMMS 
2) to establish changes or upgrades you might want to consider for your CMMS.

One of our recent studies shows – up to 94% of companies don’t use CMMS to its full capacity. Our professionals will identify key areas where improvements can be made to boost your usage and efficiency.

PHASE IV – Analysis and Report Development

The students and your Maintenance Management Professional will collaborate on analyzing the information and creating a final report. While the team co-authors the report, our staff provides most of the leg work in actually developing the report while the students provide information on what they have learned.

A completed report will be developed with final recommendations.

PHASE V - Report Presentation

Phase V includes delivery of a hard copy and electronic report.  The Maintenance Management Professional will review the results of the audit with your students, including recommended solutions for improving the efficiency of your maintenance program.  Review of the audit is conducted remotely by phone or internet presentation. 

If applicable, the Maintenance Management Professional will also support the students as they present the report to other team members and executive staff.

deliverables

1. Written maintenance process audit report with recommendations including potential benefits and savings
2. Certificate of Maintenance Management Processes and 2.4 CEUs awarded to those students who participated in the audit.
3. Professional consultation reviewing audit and report

Contact Us for a Free Consultation or Quote on Your Maintenance Management Efficiency & Process Needs.