Industrial Engineering Maintenance Capacity Planning 1 Maintenance Capacity

Industrial Engineering Maintenance Capacity Planning 1 Maintenance Capacity

Industrial Engineering Maintenance Capacity Planning 1 Maintenance Capacity Planning Industrial Engineering Maintenance Capacity Planning Maintenance capacity planning is performed to determine the optimal level of resources required to meet the forecasted maintenance load Maintenance Capacity planning procedures: Capacity Planning Techniques Determine the total maintenance load Estimate the required spare parts and material to meet the load Determine the equipment and tools necessary for all types of maintenance work

Determine the skills and the number of workers for each skill Provide special plans for highly computerized equipment Example 2 Industrial Engineering Maintenance Capacity Planning Capacity Planning Techniques Example Maintenance Capacity Planning Four basic strategies are used to match the fixed capacity with fluctuating monthly maintenance demands: 1. Chase strategy: performing the exact amount of maintenance workload required for each month, without advancing or delay 2. Levelling strategy: the peaks of demand are distributed to periods of lower demand, aiming to have a constant level of monthly maintenance activity 3. Demand management: the maintenance demand itself is levelled by distributing preventive

maintenance equally among all periods 4. Subcontracting: regular employees perform a constant level of monthly maintenance activity, leaving any excess workload to contractors 3 Industrial Engineering Maintenance Capacity Planning The Extremes Maintenance Capacity Planning Capacity Planning Techniques Level Strategy Production rate is constant Chase Strategy Production equals demand Example 4 Maintenance Capacity Planning Industrial Engineering

Sources of Craftsmen Maintenance Capacity Planning Capacity Planning Techniques Regular workers Overtime in-house workers Contract maintenance workers The best mix is determined by using cost and availability measures Example 5 Capacity Planning Techniques Industrial Engineering Capacity Planning Techniques Maintenance Capacity Planning

Deterministic models Stochastic models Capacity Planning Techniques Example 6 Capacity Planning Techniques Industrial Engineering Deterministic models: Maintenance Capacity Planning Capacity Planning Techniques Assumes the following are fixed constants: Forecasted maintenance load Standard times

Other variables Types of deterministic techniques: Example Heuristic tableau method Linear programming 7 Capacity Planning Techniques Industrial Engineering Stochastic models : Maintenance Capacity Planning Capacity Planning Techniques Assumes the following are random variables with certain probability distributions: Forecasted maintenance load

Standard times Other variables Types of deterministic techniques: Example Queuing models. Stochastic discrete event simulation 8 Industrial Engineering Capacity Planning Techniques Heuristic Tableau Method Maintenance Capacity Planning Capacity Planning Techniques For each maintenance craft, the required capacity is given by the forecasted workload for each period. The available capacity for each period is given by the quantity of available resources of different categories. Each of these categories, such as regular time, overtime, and subcontract, has its own cost.

Example 9 Capacity Planning Techniques Industrial Engineering Heuristic Tableau Method Maintenance Capacity Planning Capacity Planning Techniques Example Principles and guidelines: Maintenance work load is classified into grades according to the skill the work requires and the priority of the work. All priority work is performed by regular in-house workers as much as possible. If it is not possible to satisfy grade 1 work by regular in-house workers, use overtime.

No backlog is allowed for grade 1 work. 10 Capacity Planning Techniques Industrial Engineering Heuristic Tableau Method... Maintenance Capacity Planning Capacity Planning Techniques Example The staffing level must be determined based on the average maintenance load with a healthy backlog from grade 2 work carried out into the system. The grade 2 work can be met with overtime or contract maintenance. The overtime capacity is at most 25% of the regular inhouse capacity. The maximum for backlog is 100 man-hours. If the

backlog exceeds this limit, subcontracting is utilized and it is assumed that subcontracting can provide as much capacity as needed. 11 Capacity Planning Techniques Industrial Engineering Steps of Heuristic Tableau Method Maintenance Capacity Planning FMt = Total forecasted Maintenance load. Bt-1 = Maintenance workload backlog from period t-1 TMt = Total Maintenance workload for period t; Capacity Planning Techniques Example TMt = FMt + Bt-1 TM i,t = Total Maintenance workload of grade i in period t, i=1,2 as needed.

RM i,t = Regular in-house capacity for Maintenance workload of grade i in period t OM i,t = Overtime capacity for Maintenance workload of grade i in period t CM i,t = Contract capacity for Maintenance work of 12 Capacity Planning Techniques Industrial Engineering Steps of Heuristic Tableau Method Maintenance Capacity Planning Capacity Planning Techniques Example Cr = Hourly cost of trade on regular time Co = Hourly cost of trade on overtime

Cs = Hourly cost of subcontracting Bt = Backlog in man-hours at the beginning of period t CRt = Capacity of in-house regular time in period t COt = Capacity of in-house overtime in period t CSt = Capacity of subcontracting in period t FMt = Forecasted maintenance load in period t 13 Capacity Planning Techniques Industrial Engineering Steps of Heuristic Tableau Method Maintenance Capacity Planning Capacity Planning Techniques

Example The transportation tableau in shows the setup for a three-period planning horizon, with three resources for maintenance work in each period (m = R: regular time, m = O: overtime, m = S: subcontract). Assigning an infinite cost () prohibits assigning any maintenance work to the given (i, j) cell. After the modified transportation tableau is constructed, it is solved by the least-cost assignment heuristic. This heuristic assigns as much as possible (the minimum of supply and demand) to the available (unassigned) cell with the least cost. After each assignment, the supply and demand for the given cell are updated, and the process continues until all demands have been assigned. Although this technique does not guarantee an optimum solution, it is an effective heuristic that frequently leads to optimum solutions. 14 Capacity Planning Techniques Industrial Engineering Maintenance Capacity Planning Capacity Planning Techniques Periods

Period Sources 1 2 3 Capacity 1 Regular Time Cr CR1 Overtime Co CO1 Subcontract Cs

CS1 Regular Time Cr + Cr CR2 Overtime Co + Co CO2 Subcontract Cs + Cs CS2 Regular Time Cr + 2 Cr +

Cr CR3 Overtime Co +2 Co + Co CO3 Subcontract CS + 2 Cs + Cs CS3 Maintenance load M1 M2 M3 2 3 Example

15 Industrial Engineering Example Maintenance Capacity Planning Capacity Planning Techniques Example 16 Industrial Engineering Example Maintenance Capacity Planning Capacity Planning Techniques Example 17

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