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2005 SMRP Conference St Louis, Missouri

Maintenance Planning

The Perfect Job Plan


R. D. (Doc) Palmer, PE, MBA, CMRP
Author – McGraw-Hill’s
Maintenance Planning and Scheduling Handbook

John C. Pearl, PE, MBA, CMRP


Collection System Operations Division Manager (retired)
Central Contra Costa Sanitary District
Foundations

 Planner Expertise
 Repeated Maintenance Work

Doc Palmer
Planner Expertise
Florida Planner California Planner
Type A Low Key
Git R Done Develop Relationships
Good Communicator Ditto
Self-Starter Ditto
Anti-Status Quo Ditto
Top Mechanic Ditto
Good Organizer Ditto
Good with Computer Ditto
Good with Files Ditto
Respect of Crafts Ditto
Doc Palmer
Repeated Maintenance Work

Do Job

Plan Learn

Feedback

Doc Palmer
The Plan

Do Job

Plan Learn

Feedback

Doc Palmer
WORK ORDER #001234
REQUESTER SECTION

PLANNING SECTION
The typical
sections of a
work order
CRAFT FEEDBACK
SECTION
CODING SECTION
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION

An originator
writes a work
order request

CRAFT FEEDBACK

APPROVAL:
CODING

Doc Palmer
Plant schematic shows function and location of the tank & gate

001

West
Doc Palmer Forebay
Doc Palmer
Doc Palmer
Permanent identification tags on
all equipment match file and
Doc Palmer
computer records
DEFICIENCY TAG The originator hung
#010304 a deficiency tag to
EQUIPMENT
mark the equipment
EQUIP TAG # written on the work
PROBLEM order request.

Carbon &
LOCATION Copy
TAGGED BY
DATE
TIME

Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION

Planners add
codes to new
work orders
to aid reporting.
CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
Create paper file the first time equipment has
a work order. The file number matches the
tag number hung on the equipment.

4
1 West Forebay Tank Outlet Gate File Created 4/22/98 by Lee

1
1
2

Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate. Plan for the
Day 1 – Set up & drain
Day 2 – Hose down level of detail
Day 3 - Fix gate and adjust.
Remove/store equip
that a skilled
craftsperson
would need

Planner D. Lee 9/11/98

CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers Plan for the
Day 2 – Hose down 3 Utility Workers minimum
Day 3 - Fix gate and adjust. 1 Mech 3rd Class
1 Mech 1st Class craft skill
Remove/store equip 2 Utility Workers
Labor: Mech 3rd Cl level needed
Mech 1st Cl
Utility Wrkr

Planner D. Lee 9/11/98


CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr
Use past craft Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip
experience to Utility Wrkr 37hr

estimate the
time for a
smooth job by Planner D. Lee 9/11/98
CRAFT FEEDBACK
a good craft-
person. APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr
Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip Plan anticipated
Utility Wrkr 37hr
Parts: gate guide #7843-2 Qty 1 Cost $859 parts and reserve
if necessary.
Show cost.
Planner D. Lee 9/11/98
CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr
Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip Plan anticipated
Utility Wrkr 37hr
Parts: gate guide #7843-2 Qty 1 Cost $859 special tools and
Tools: 4” trash pump, 2 suction hoses, 5 discharge hoses,
bolts: naval bronze-record qty & size:__________
consumables.
Fall protection equip, 24’ ladder
Planner D. Lee 9/11/98
CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr
1 Mech 1st Class 4 Hr Estimate the
Remove/store equip 2 Utility Workers 4 Hr
Labor: Mech 3rd Cl 4hr Total labor 45 Hr total job cost to
Mech 1st Cl 4hr Job duration 2.5 Day for equip
Utility Wrkr 37hr allow scrutiny
Parts: gate guide #7843-2 Qty 1 Cost $859
Tools: 4” trash pump, 2 suction hoses, 5 discharge hoses,
of costly jobs.
bolts: naval bronze-record qty & size:__________
Fall protection equip, 24’ ladder
Planner D. Lee 9/11/98 Job estimate: $3109
CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
Do Job

Plan Learn

Feedback

Doc Palmer
Do Job

Plan Learn
Feedback

Doc Palmer
Do Job

Plan Learn

Feedback
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98 Technicians
PLANNING SECTION “Non-permitted Confined Space.” provide feedback
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr for history and
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr plan improvement.
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr
Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip
Utility Wrkr 37hr
Parts: gate guide #7843-2 Qty 1 Cost $859
Tools: 4” trash pump, 2 suction hoses, 5 discharge hoses,
bolts: naval bronze-record qty & size:12- ¾” UNC
Fall protection equip, 24’ ladder
Planner D. Lee 9/11/98 Job estimate: $3109
CRAFT FEEDBACK
Replaced track on gate. Used boom truck for guide.
Mech 3rd Cl 2x3hr. Utility 2x4hr, 3x5hr, 2x3hr
C. Jones 4/23/98 APPROVAL: L. Vincent 4/23/98
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #001235
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is binding and does not
operate properly. Def. Tag #010304. No outage required.
Needs mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 4/21/98 Record actual
PLANNING SECTION “Non-permitted Confined Space.” total job
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr cost to allow
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr better asset
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr management.
Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip
Utility Wrkr 37hr
Parts: gate guide #7843-2 Qty 1 Cost $859
Tools: 4” trash pump, 2 suction hoses, 5 discharge hoses,
bolts: naval bronze-record qty & size:12- ¾” UNC
Fall protection equip, 24’ ladder
Planner D. Lee 9/11/98 Job estimate: $3109 Actual $2609
CRAFT FEEDBACK
Replaced track on gate. Used boom truck for guide.
Mech 3rd Cl 2x3hr. Utility 2x4hr, 3x5hr, 2x3hr
C. Jones 4/23/98 APPROVAL: L. Vincent 4/23/98
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
The Perfect Plan

Do Job

Plan Learn

Feedback

Doc Palmer
WORK ORDER #002107
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is stuck.
Def. Tag #037114. No outage required.
Mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 9/11/98 Plants work
PLANNING SECTION on the same
equipment
repeatedly.

CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
Improving the Plan

Do Job

Plan Learn

Feedback

Doc Palmer
WORK ORDER #002107
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is stuck.
Def. Tag #037114. No outage required.
Mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 9/11/98 Improve the
PLANNING SECTION “Non-permitted Confined Space.” previous plan
Gate came out of guides. Drain & clean tank. Fix gate.
Day 1 – Set up & drain 2 Utility Workers 4 Hr by assessing
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr feedback
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr
Information.
Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip
Utility Wrkr 37hr Continuously.
Parts: gate guide #7843-2 Qty 1 Cost $859
Tools: 4” trash pump, 2 suction hoses, 5 discharge hoses,
bolts: 12 -3/4” UNC naval bronze std hex
Fall protection equip, 24’ ladder, boom truck
Planner D. Lee 9/11/98 Job estimate: $3109
CRAFT FEEDBACK

APPROVAL:
CODING Plan Type: R System: Tertiary Crew: Mech
Work Type: RM Equip Type: Tank Outage: 0
Doc Palmer
WORK ORDER #002107
REQUESTER SECTION Priority 3
West Forebay Tank Gate (41112) is stuck.
Def. Tag #037114. No outage required.
Mech crew. Clearance Req. No Confined Space.
J. Smith 4/21/98 3:00pm.APPROVAL: S. Brown 9/11/98 Add reference
PLANNING SECTION “Non-permitted Confined Space.”
Gate came out of guides. Drain & clean tank. Fix gate.
and history
Day 1 – Set up & drain 2 Utility Workers 4 Hr section to
Day 2 – Hose down 3 Utility Workers 7 Hr
Day 3 - Fix gate and adjust. 1 Mech 3rd Class 4 Hr encourage
1 Mech 1st Class 4 Hr
Remove/store equip 2 Utility Workers 4 Hr feedback.
Labor: Mech 3rd Cl 4hr Total labor 45 Hr
Mech 1st Cl 4hr Job duration 2.5 Day for equip
Utility Wrkr 37hr
Parts: gate guide #7843-2 Qty 1 Cost $859
Tools: 4” trash pump, 2 suction hoses, 5 discharge hoses,
bolts: 12 -3/4” UNC naval bronze std hex
Fall protection equip, 24’ ladder, boom truck

***Special Reference and Procedure History Section****


Reference (not needed on job): ACME Mnl #7 pg 14
Job Plan/Procedure History:
04/25/98 Added bolts qty/size, boom truck per fdbk. Lee
Planner D. Lee 9/11/98 Job estimate: $3109
Doc Palmer
Doc Palmer
Maintenance Planning

The Perfect
Job Plan
Doc Palmer
Brunswick, Georgia
docpalmer@palmerplanning.com
John Pearl
Walnut Creek, California
mcpearl@astound.net

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