| List of Figures | p. xi |
| List of Tables | p. xv |
| Acknowledgement | p. xvii |
| 1 Historical View of Maintenance | p. 1 |
| 1.1 Pure Reactive | p. 3 |
| 1.2 Limited Proactive Applications | p. 5 |
| 1.3 Birth of Real Maintenance | p. 6 |
| 1.4 Military Takes the Lead in Maintenance | p. 10 |
| 1.5 Long Journey to Lean Thinking | p. 12 |
| 1.5.1 Lean Spills Over to Maintenance | p. 15 |
| 1.5.2 Maintenance Operation Refinements | p. 16 |
| 2 The Plant/Facility Lean Environment | p. 19 |
| 2.1 Lean Origins and Definitions | p. 19 |
| 2.2 Lean Organization: Elements and Practices | p. 22 |
| 2.2.1 Current State | p. 25 |
| 2.2.2 Future State | p. 26 |
| 2.3 Lean Maintenance Operations | p. 28 |
| 2.3.1 Fundamentals of Total Productive Maintenance | p. 29 |
| 2.3.1.1 Work Execution | p. 33 |
| 2.3.1.2 Planning and Scheduling | p. 34 |
| 2.3.1.3 Reliability Engineering | p. 34 |
| 2.3.2 Lean Refinements | p. 35 |
| 2.3.2.1 Reliability Excellence | p. 35 |
| 2.3.2.2 Teams and Teamwork | p. 36 |
| 2.3.2.3 New Roles for Managers and Supervisors | p. 38 |
| 2.3.2.4 Organizational Focus | p. 38 |
| 2.3.2.5 Expanded Education and Training | p. 39 |
| 2.3.2.6 Maintenance Optimization | p. 39 |
| 2.3.3 Lean Maintenance: Prerequisite of the Lean Plan/Facility | p. 41 |
| 3 Governing Principles and Concepts of Lean Maintenance | p. 42 |
| 3.1 Lean Maintenance Governing Principles and Concepts | p. 43 |
| 3.1.1 Vision and Mission | p. 45 |
| 3.1.2 Strategic Plans, Goals and Targets | p. 46 |
| 3.2 Operations and Maintenance | p. 48 |
| 3.2.1 Operations Maintenance-A Partnership with Two-Way Responsibilities | p. 48 |
| 3.2.2 A Lean Mandated Marriage | p. 51 |
| 3.3 Why Plan? | p. 58 |
| 3.3.1 Advantages of Maintenance Planning | p. 58 |
| 3.3.2 Objectives and Goals of Maintenance Planning | p. 61 |
| 4 Origins of the Maintenance Planner | p. 63 |
| 4.1 In the Beginning | p. 63 |
| 4.2 Developing Standard Practices | p. 65 |
| 4.2.1 Basic Process | p. 65 |
| 4.2.2 Manufacturing's Influence | p. 70 |
| 4.2.2.1 Accommodating a Varying Workload | p. 71 |
| 4.2.2.2 Resources, Resources, Resources | p. 74 |
| 4.2.3 Appearance of Balance | p. 75 |
| 5 Organization Alternatives | p. 78 |
| 5.1 Styles for Organizing Maintenance Operations | p. 80 |
| 5.1.1 Style Variations | p. 81 |
| 5.1.1.1 Trade Organization | p. 81 |
| 5.1.1.2 Area Organization | p. 83 |
| 5.1.1.3 Production Department Maintenance | p. 84 |
| 5.1.1.4 Joint Trade and Area Organization | p. 87 |
| 5.1.1.5 Contract Maintenance - Partial or Total | p. 88 |
| 5.1.1.6 Organization by Work Type | p. 90 |
| 5.1.1.7 Combination Styled Organization | p. 92 |
| 5.1.2 Total Productive Maintenance | p. 95 |
| 5.1.3 Reliability-Centered Maintenance | p. 98 |
| 5.1.3.1 Incorporating Work Planning | p. 104 |
| 5.1.3.2 Planning and Scheduling: Defining the Role | p. 108 |
| 5.2 TPM-RCM-Lean Organizational Considerations and Choices | p. 109 |
| 5.2.1 Where Does the Planner Fit? | p. 111 |
| 5.2.1.1 Erroneous Thinking | p. 113 |
| 5.2.1.2 The Reality | p. 113 |
| 5.2.1.3 The Assigned Tradesperson | p. 114 |
| 5.2.1.4 The Responsible Supervisor (or Team Leader)? | p. 114 |
| 5.2.1.5 Fostering a Sense of Accomplishment | p. 116 |
| 6 Performing the Planning Function | p. 118 |
| 6.1 Principles of Planning | p. 119 |
| 6.1.1 Managing the Backlog | p. 120 |
| 6.1.2 Criticality and Prioritization | p. 122 |
| 6.1.3 The Work Order | p. 130 |
| 6.1.3.1 Work Order Types and Formats | p. 130 |
| 6.1.3.2 Work Order System and Work Flow | p. 133 |
| 6.1.3.3 Coding Work Order Information | p. 136 |
| 6.1.4 Sequence of Planning | p. 150 |
| 6.1.4.1 Job Plan Level of Detail | p. 151 |
| 6.1.4.2 The Work/Job Package | p. 154 |
| 6.1.4.3 Estimating and Work Measurement | p. 161 |
| 6.1.4.4 Planning Aids | p. 167 |
| 6.1.5 The Role of CMMS in Maintenance Planning | p. 169 |
| 6.1.6 Feedback | p. 171 |
| 6.1.6.1 Building a History | p. 178 |
| 6.2 Closing Out Work Orders | p. 181 |
| 6.2.1 Data Entry and Validation | p. 182 |
| 6.2.2 Reliability Engineering | p. 183 |
| 6.3 Lean Maintenance Planning | p. 187 |
| 7 Performing the Maintenance Scheduling Function | p. 189 |
| 7.1 Scheduling | p. 189 |
| 7.2 Organizational Considerations | p. 190 |
| 7.3 Scheduling Defined | p. 193 |
| 7.3.1 Prerequisites for Effective Scheduling | p. 195 |
| 7.3.2 Preparing Schedules | p. 196 |
| 7.3.2.1 Scheduling Practices | p. 197 |
| 7.3.2.2 Scope of Maintenance Scheduling | p. 199 |
| 7.4 Metrics-Schedule Compliance and Labor Effectiveness | p. 205 |
| 7.5 General Scheduling Considerations | p. 209 |
| 8 Special Case: Maintenance Planning and Scheduling for Maintenance Outages - The Plant Shutdown | p. 211 |
| 8.1 Planned Outages Defined | p. 213 |
| 8.1.1 Phase I: Definition | p. 213 |
| 8.1.2 Phase II: Planning | p. 216 |
| 8.1.2.1 Purchasing: Plant Shutdown Logistics | p. 219 |
| 8.1.3 Phase III: Scheduling | p. 220 |
| 8.1.4 Phase IV: Execution | p. 222 |
| 8.1.5 Phase V: Debrief and Lessons Learned | p. 223 |
| 8.2 Critical Path Method Scheduling | p. 224 |
| 9 Tips, Tricks and Avoiding Pitfalls | p. 230 |
| 9.1 Straight from the Horse's... | p. 230 |
| 9.2 Gaining Trust | p. 230 |
| 9.2.1 Maintenance Planner | p. 230 |
| 9.2.2 Maintenance Scheduler | p. 232 |
| 9.2.3 Attitudes, Practices and Methodologies for Success | p. 233 |
| 9.2.3.1 Empowerment and Areas of Responsibility | p. 233 |
| 9.2.3.1 Skill Levels and Training | p. 235 |
| 9.2.4 Tips and Tricks of Successful Planners and Schedulers | p. 237 |
| 9.2.4.1 Maintenance Planner | p. 237 |
| 9.2.5 Maintenance Scheduler | p. 239 |
| 10 Metrics: Measuring Planning and Scheduling Performance | p. 241 |
| 10.1 Planning and Scheduling Performance Indicators | p. 242 |
| 10.1.1 Labor Performance | p. 242 |
| 10.1.2 Job Planning and Scheduling | p. 243 |
| 10.2 Reliability Excellence (Rx) and the P/S Function | p. 244 |
| 10.3 Summary: Characteristics of Reliability Excellence | p. 246 |
| 11 Planning and Scheduling Fundamentals - Self-Test | p. 249 |
| 11.1 Approach | p. 249 |
| 11.2 Self-Test Question and Answer Section | p. 250 |
| 11.3 Self-Test Work Exercise Section | p. 253 |
| Appendix A Job/Position Descriptions | p. 255 |
| Appendix B Benchmarking and Best Practices | p. 261 |
| Appendix C Forms, Worksheets and Checklists | p. 266 |
| Appendix D Tutorials in Brief: Control Charts and CPM Schedules | p. 282 |
| Appendix E Chapter 11 Self-test: Answers and Solutions | p. 294 |
| Appendix F Glossary | p. 298 |
| Index | p. 325 |