Kaizen Institute South Africa introduces Mexcellence Maintenance Planning and Scheduling (MPS) Master Class

Kaizen Institute South Africa has introduced a two-day Mexcellence Maintenance Planning and Scheduling (MPS) Master Class aimed at boosting the productivity of maintenance teams by up to 50%, facilitating predictive maintenance and reduced machine failures in the process.

“The primary objective of KAIZEN™ Mexcellence MPS Master Class is to improve the productivity of maintenance technicians and to assist companies to move from a reactive to proactive work culture,” says Mbuso Nkosi, Managing Director of Kaizen Institute South Africa.

“Productivity (measured as wrench time) of plant maintenance technicians working reactively is generally below 30%. This means that a mechanic for example, working an average eight-hour day, spends just two hours 25 minutes doing value added work. The balance of five hours 35 minutes get wasted in sourcing and waiting for parts, or instructions, delays in obtaining permits, travelling etc.,” he says.

“In general, an unplanned maintenance job costs 1.1 to 1.3 times more to one that’s planned, while an emergency job costs three to five times more to one that’s planned,” Nkosi adds.

Maintenance planning and scheduling is a systematic, simple, cost effective and time-tested methodology of improving equipment reliability, availability while reducing maintenance costs.

By following MPS, delays during and between jobs get reduced. As a result, the productivity or wrench time of maintenance teams or individuals increases to 50 % and above.

This helps maintenance departments to undertake more proactive work such as preventive and predictive maintenance, defect Identification, modifications etc. By carrying out more proactive maintenance activities, failures of the equipment are reduced. In addition, plant safety improves, as does the work-life balance of maintenance team members.

“The two-day Mexcellence MPS Masterclass will help participants to understand best practice in maintenance planning and scheduling as followed by world class companies around the globe. The participants will also be able to put the knowledge gained to practical use at their own workplaces,” Nkosi says.

This helps maintenance departments to undertake more proactive work such as preventive and predictive maintenance, defect Identification, modifications etc. By carrying out more proactive maintenance activities, failures of the equipment are reduced. In addition, plant safety improves, as does the work-life balance of maintenance team members.


Course Content: Day One


Attendees will learn:

Introduction

Maintenance Concepts 

Work Management

Work Identification

Work Prioritization

Backlog Management 

Planning 


Course Content: Day Two


Attendees will learn:

Scheduling

Work Execution

Work Order Closure and Documentation

Work Order Status Control and Continuous Improvement 

Meetings

Materials Management

Preventive Maintenance

CMMS

Test Questions and Answers


What attendees will learn:


How to measure your maintenance effectiveness 

What maintenance planning and scheduling is, why it is required and how to implement it 

How to develop a detailed job plan 

Understand roles and responsibilities of a planner and scheduler. 

How to manage maintenance backlog 

Understand how to assess your current maintenance work management practices 


Symptoms that your plant needs attention [to be placed in a box]


Are emergencies and equipment breakdowns in your plant too frequent to be controlled? 

Is the condition of your equipment becoming progressively worse? 

Do you feel your maintenance department is always short of manpower and spares? 

Is your overtime cost high? Are maintenance work orders piling up? 

Are most work requests being marked as urgent? 

Are your maintenance costs ever increasing? 

Is preventive maintenance of the equipment getting neglected because of maintenance crew are too busy fire fighting? 


If any of these symptoms exist in your plant, we would strongly recommend attending this program.

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