CMRP Exam Prep for Pillar 5: Maintenance Work Management

Identify maintenance needs and submit a work request by the operations team, using a CMMS to initiate work order, while predictive and preventive teams may also identify and submit requests.

Identify work request categories, including corrective maintenance, preventive maintenance, predictive maintenance, and equipment upgrade, and learn how categorization enables CMMS-driven analysis and informed maintenance strategies.

Track maintenance performance by calculating shares of corrective, preventive, and condition based maintenance costs and hours, including failure finding tasks and shutdown costs, to monitor trends and improve proactive planning.

Discover how maintenance work orders are prioritized through a formal, standardized process that assigns emergency, urgent, and routine priorities to guide execution.

Discover how maintenance planning defines needed labor, tools, and parts to boost wrench time and reduce unproductive tasks, improving efficiency and productivity in maintenance work management.

Learn how job plan and job scoping define the work, estimate time and manpower, and ensure accurate maintenance planning to avoid deviations and wasted wrench time.

Learn to estimate a work order cost by summing labor, parts, and tools or consumables, and track estimating accuracy and planning variance index with a cms.

Explore how a job plan library and templated plans streamline maintenance work, saving time, enabling reuse, and driving continuous improvement in planning accuracy.

Maintenance planners ensure parts, tools, and materials meet quality assurance and quality control standards, are available, procuring when needed, making the work order ready for scheduling.

Learn how parts kitting and parts staging—though not mandatory—place kits near the job site to boost wrench time and reduce trips to the technical store.

Implement a simple, secure file system by equipment tag numbers to store historical data for repetitive maintenance and use file cost information to guide repair or replacement decisions.

Leverage top-level technicians' hands-on experience and file information to develop work plans, avoiding pigeonholing with standards and boosting wrench time and labor productivity.

This principle recognizes the crafts' skills, with planners defining the job scope and clarifying the originator's intent while leaving the how to the skilled technicians. Feedback matures the plans.

Learn how maintenance scheduling creates a weekly backlog, prioritizes work, and allocates technician hours to maximize plant productivity and ensure planned hours are used.

Identify the first principle of maintenance scheduling: specify job plans with number of persons, lowest required skill level, craft hours per skill, and total job duration for advanced scheduling.

Have a dedicated scheduler produce a one-week list of work orders based on forecasted craft hours, skill levels, and priorities, including proactive and reactive tasks on the same equipment.

Schedule every available work hour for the week, including interruptible tasks to cushion emergencies, and align with forecasted hours while prioritizing high-priority work even if it lowers skill levels.

Explore scheduling metrics for preventive and predictive maintenance, defining timely completion with configurable criteria, tracking overdue work orders by criticality, and analyzing work order variance to boost compliance.

Develop a shutdown, turnaround, and outage plan by sequencing related work orders, and tracking progress with burndown, Gantt, and PERT charts to ensure timely return of equipment.

Learn how production planning concepts like work centers, capacity, and bottlenecks apply to maintenance scheduling; use level loading (Heijunka) and labor loading to spread work evenly across days and teams.

Explore the maintenance work execution phase and the critical role of craft feedback in improving work plans, with CMMS enabling detailed findings and root cause analysis.

Explore skills assessment, tracking, and training to manage maintenance staff and close skill gaps. Map required skills to roles and monitor competency levels to boost plant effectiveness.

Learn how yield and effectiveness measure the quality of preventive and predictive maintenance by linking identified corrective work to maintenance hours and validating work orders.

Classify inventory by usage frequency and cost to support maintenance work management; identify active, infrequently used, and rarely used items, and apply ABC categorization (A, B, C) for spares.

Learn key inventory management concepts, including ordering cost, carrying cost, economic order quantity, and total annual inventory cost within a fixed order quantity system.

Master materials requirements planning, demand forecasting methods, and bill of materials for maintenance; optimize lead time, inventory turnover, storage, cycle counts, and ABC classification for spare parts.

Explore inventory management metrics for maintenance, focusing on stockouts and inactive stock. Learn to calculate stockout and inactive stock rates, excluding critical and non-stock parts, with targets under 2% and under 1%.

Develop maintenance work management through gap analysis and digital work requests, implement asset tagging, and apply theory of constraints and pdca for continuous improvement toward proactive maintenance.