Maintenance Work Management Fundamentals (CMRP Pillar 5)

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.

Approve or decline work requests in the work management system to prevent duplication and pre-decided actions, and communicate rejection reasons to the initiator.

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

Explore formal work prioritization methods for maintenance, including asset criticality, time index ranking, rhyme index, and Moscow technique, to rank and prioritize work orders effectively.

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.

Develop a safety plan within a job plan, including hearing protection and jet engine hazard distances, to give technicians a head start and improve wrench time.

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.

Explore maintenance planning metrics such as ready backlog, planned backlog, and work order aging, and learn how cycle time, standing orders, and follow up drive reliable weekly 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.

Explore the six principles of maintenance planning, including a separate department for planners to focus on future work and maintaining a one-week backlog ready to execute.

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.

Explore the sixth principle of maintenance planning, defining wrench time as the primary measure of workforce efficiency and planning effectiveness, and distinguish planning from scheduling to reduce delays.

Explore maintenance planning metrics, including planned work percentage, unplanned work, planner productivity, and craft worker to planner ratios, with best-in-class targets and monthly to quarterly benchmarks.

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.

Learn the second principle of maintenance scheduling: adhere to weekly and daily schedules, assign proper priorities to new work orders, and prevent break in work caused by emergency tasks.

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 how the maintenance crew supervisor crafts a daily schedule ahead of time, handles emergencies, and assigns skilled personnel; examine wrench time and schedule compliance as measures of planning effectiveness.

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.

Apply lockout tagout and safety work permits to protect maintenance personnel during execution. Integrate safety into the Famous Five methodology and Rams study to safeguard reliability, availability, and maintainability.

The maintenance supervisor prioritizes daily work from the schedule, assigns tasks to technicians, ensures quality workmanship, mentors apprentices, and oversees a ratio of 12 craft workers per supervisor.

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.

Learn key human resource metrics for maintenance management, including direct versus indirect personnel ratios, FTE calculations for contracted services, and overtime, shift, and cost benchmarking toward best-in-class targets.

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%.

Examine vendor managed inventory and maintenance material cost, including MRO stock, SKU ratios, and the share of material cost in total maintenance expenses.

Explore inventory management metrics for maintenance, detailing storeroom transactions and the benchmarks per clerk, with bar coding assumptions, and analyze storeroom records per storekeeper using SKUs.

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.

Explore the overall work management process from identification to execution, master the six maintenance planning and scheduling principles, and learn CMP exam essentials like acronyms, rhyme index, and Moscow.