Work Planning & Control Overview

Defining Required Maintenance Tasks Executing Maintenance Tasks Capturing Maintenance History Improving Maintenance Identify Ad-Hoc Maintenance Tasks
1 Report Faults Fault Reporting Procedure

Non-tactical Maintenance
2 Operator Repair First Line Maint. Procedure

Continuous Improvement
13 Identify Maintenance Optimisation Opportunities

Incident Log Observations 3 Emergency Repair Emergency Maint. Procedure

14 Maintenance Optimisation Problem Solving Procedure

12 Close-Out Work Order Close-out Procedure

MIMS

Tactical Maintenance
5 Operator Checks Daily Routine Checks 6 Do PM Maintenance Preventative Maint. Procedure 7 Do Predictive Maintenance Predictive Maint. Procedure

15 Update MIMS

16 Performance Monitoring KPI Monitoring Procedure

Planning Inputs:

Planned Maintenance Schedules Unscheduled Work Orders (from PM, PDM feedback) Outstanding Work Orders Backlog (of scheduled Work Orders) Production Demand (Ops Plan) 4 Plan & Schedule Jobs Planning Procedure

17 Engineering Change Management

8 Repair by UHAR UHAR Repair Procedure

Outputs:
Ops Plan 5 yr plan 1 yr plan 3 month plan Weekly plan Opportunity Planning Overhaul Planning Workload smoothing Resource planning Etc.

9 Repair by Contractor Contractor Repair Procedure 10 Overhaul Unit (UHAR) Unit Overhaul. Procedure 11 Do Corrective Maintenance Corrective Maint. Procedure

Improving Maintenance

Continuous Improvement
13 Identify Maintenance Optimisation Opportunities

14 Maintenance Optimisation Problem Solving Procedure

MIMS

15 Update MIMS

16 Performance Monitoring KPI Monitoring Procedure

17 Engineering Change Management

1.0 Fault Reporting

Any Person 1.1 If you see a fault, ID the equipment no & report it the Operator Operator 1.2 Is the fault recorded? No Operator MIMS 1.5 Notify Sup Ops Operator

Yes

Operator 1.3 Notify Fault Reporter that fault is logged already.

1.4 Log fault on MIMS Incident Log MSO627: Complete as far as possible: add production work group name Date operation shift, equipment number exact time of finding detailed problem description maintenance type required FLM Sup Name where applicable

Ops Sup Ops Sup 1.6 Can it be rectified by First Line Maintenance? No Ops Sup Ops Sup Emergency if: 1.8 Serious Does it Safety Risk require Unit Trip Emergency 20%+ Derated Repair? Will cause trip / 20%+ deration No if not repaired within 48 hrs Yes MIMS Ops Sup Ops Sup 1.10 Day Time? No 3.1 EM 1.11 Report to Tech Cr Maint Ops Sup Yes 1.7 Notify Operator to carry out the required First Line Maintenance 2.1 FLM

1.9 Raise a Work Order on MIMS (MSO627 action W) and assign to a work group.

Yes

1.12 Report to Sup Cr Maint

4.5.1 P&S

Ops

2.1 FLM

Ops Sup 3.1 EM 1.11 Report to Tech Cr Maint Ops Sup

No

1.12 Report to Sup Cr Maint

4.5.1 P&S

2.0 First Line Maintenance

Operator 1.7 FR 2.1 Record Incident No in Operators workbook Operator 2.2 Investigate job to determine what tools and material are required Operator 2.3 Material required? Yes Ops Sup MIMS

No

2.4 Issue General Material requisition using standard WO per unit MSQ140 & MSO62Q action I

Operator 2.6 Collect Tools & spares if required, then carry out maintenance

Operator 2.7 Record all findings (failure, cause, corrective action, material usage) on WO / workbook & return to Ops Sup

Ops Sup Yes MIMS

DM Prod MIMS

al d?

2.4 Issue General Material requisition using standard WO per unit MSQ140 & MSO62Q action I

2.5 Authorise Material requisition using standard WO per unit MSQ140 & MSO62Q action I

Operator 2.7 Record all findings (failure, cause, corrective action, material usage) on WO / workbook & return to Ops Sup

Operator 2.8 Return unused parts to store

Ops Sup MIMS

13.1

13.2 2.9 Close Incident Log MSO627

3.0 Emergency Maintenance

Sup Cr Maint 1.11 FR Tech Cr Maint 3.1 Do a Field Inspection 1.12 FR Location Surrounding Area Equipment Status Facility Availability Other related equipment Safety Factors 3.2 Notify / Report to Sup Cr Maint Tech Cr Maint 3.3 Can UP Fix problem? No Sup Cr Maint MIMS

Sup C

Yes

3.4 Change Responsible Work Group to UHAR

No

Tech / Sup Cr Maint Printer 3.6 Print Job Card

Tech CR Maint 3.7 Obtain a work permit

Tech / Sup Cr Maint 3.8 Raise Manual Requisition for Material

Foreman Cr Maint MIMS

Sup C

3.9 Material & Spares Requisition MSQ140 / MSQ Action I

Tech CR Maint Tech Cr Maint 3.11 Spares / Resources Available? Yes 3.12 Collect Tools, Spares, etc as required for Job Tech Cr Maint 3.13 Perform required Maint. Job

Tech Cr Maint 3.14 Record all findings (failure, cause, corrective action, material usage) on WO / workbook & return to Ops Sup

No

Tech CR Maint MIMS

Tech CR Maint

Tech CR Maint 3.18 Stage & Source Spares / Resources.

3.16 Update Job Status Awaiting Spares

3.17 Notify Sup Ops & Sup CR Maint

Tech CR Maint 3.20 Close work permit Sup Cr Maint 3.21 Evaluate and verify job feedback on Job Card Sign-off 3.22 Deliver Completed Job Card to Planner Sup Cr Maint

Sup Cr Maint 3.15 Job Completed?

Yes Sup Cr Maint

No

Sup Cr Maint 3.15 Job Completed?

3.20 Close work permit Sup Cr Maint 3.21 Evaluate and verify job feedback on Job Card Sign-off 3.22 Deliver Completed Job Card to Planner 3.19 Notify Sup Prod that job is completed Sup Cr Maint

Yes Sup Cr Maint

No

Sup Cr Maint No MIMS

Sup Cr Maint 8.2 UHAR 3.5 Notify UHAR

3.4 Change Responsible Work Group to UHAR

Foreman Cr Maint MIMS

Sup Cr Maint MIMS

3.9 Material & Spares Requisition MSQ140 / MSQ Action I

3.10 Approve Requisition

ech Cr Maint 3.14 Record all findings (failure, cause, corrective action, material usage) on WO / workbook & return to Ops Sup

Tech CR Maint 3.18 Stage & Source Spares / Resources.

p Cr Maint 12.1 CWO

3.22 er Completed Job Card to Planner

p Cr Maint 12.1 CWO

3.22 er Completed Job Card to Planner

6.0 Preventive Maintenance

Sup PM Sup PM 6.2 Job Card require general materila? 6.1 Receive Job Cards Yes Sup PM MIMS DM Maint MIMS DM Maint 6.5 Requisition Approved? Yes

No

6.3 Raise Requisitions General Material MSO140 & MSO620 Action I

6.4 Approve Requisitions for General Material

No

Tec Foremen PM 6.7 Allocate Job Cards to PM Technicians Tech PM 6.8 Collect Tools, Gen Materials, etc as required for Job Tech PM 6.9 Obtain Permit to Work from Sup Ops Tech PM 6.10 Execute work

6 Any oth iden

Tech PM 6.12 Record all findings on job card including corrective actions required & material usage. Return to Sup PM

Sup Ops 6.13 Close work permit

Sup Ops

Tech PM 6.15 Return Tools

Sup PM

6.14 Approve Job Feedback

6.16 Evaluate and job feedbac Job Car Sign-o

DM Maint 6.5 Requisition Approved? Yes

Sup PM 6.6 Distribute Job Cards to applicable Foremen

ve ns for aterial

No

Tech PM

Tech PM 6.10 Execute work 6.11 Any other faults identified? Yes 1.1

No

h PM

Sup PM 6.16 Evaluate and verify job feedback on Job Card Sign-off 12.1 CWO

6.15 Return Tools

4.0 Maintenance Planning

Yearly 4.1 Develop 5 year Plan Quarterly Planned Outage Scheduling 4.2 Develop Plan of the Year Monthly Yearly PM & PdM Schedule & Load Balancing Yearly Maintenance Budget 4.3 Develop Plan of the Quarter Weekly Detail Planning & Scheduling of individual Outages First Line Maintenance Work Orders Monthly Schedule & Load Balancing 4.4 Develop Plan of the Week Daily

Work outside Outages not urgent (required after 7 days) Preventative Maintenance UHAR Contractor Corrective

4.5 Develop Plan Day

Work outsid Outages urgent (re in less than

Preventat Maintenan UHAR Corrective

ekly

4.4 elop Plan of the Week Daily 4.5 Develop Plan of the Day

rk outside tages not urgent quired after 7 ys)

Preventative Maintenance UHAR Contractor Corrective

Work outside Outages urgent (required in less than 7 days) Preventative Maintenance UHAR Corrective

4.5 Planning & Scheduling

Daily
12.5 WCO Morning Meeting 5.9 OC 4.5.1 Discuss Incident Log to identify maintenance actions required DM Maint / Ops Ops Sups Ops Plan Sup Maint. Sups Maint Plan Sup UHAR Plan Sup Eng Coordinator Planners Planner UP MIMS Planner MIMS 4.5.15 Outage Planning

4.5.2 Raise a Work Order on MIMS (MSO627 action W) and assign to a work group. 4.4.1 P&S WKL

4.5.3 Extract list of work orders to be done in next 7 days (from Morning Meeting)

Last week before outa Follow-up on Specific orders

Planner 4.5.4 From WOs raised, Identify additional PM Tasks to be done today Planner Planner 4.5.8 ID additional tasks (planning completed) to be done during Forced Outage Planner

Plan the Jobs make sure that all the material and resources (Spares, Additional PMs Support Equipment, required People, Time required to complete a Job) are available, complete with the 4.5.5 detailed task Corrective instructions, BEFORE Maintenance scheduling a job and Planning issuing the jobcard.

4.5.7 Yes Is a forced outage required to do a job?

4.5.9 Negotiate outag time & duration w Ops Planner & Dispatcher.

This will result in more effective use of limited WOs from reported faults WOs resulting from PMs and and valuable PdMs maintenance manhours by reducing 4.5.6 wasted maintenance Repair by UHAR man-hours through Planning preventing starting a job and then have to wait for material and WOs from reported faults other resources. WOs resulting from PMs and PdMs

No Planner 4.5.10 Complete Planning & Schedule tasks for today Do resource smoothing Job Description Check with Weekly Plan Planning Sup MIMS Planner MIMS

4.5.11 Upload schedule into MIMS

Plan Planner Printer 4.5.13 Print Job Cards

4.5.12 Approve Work Orders

Dist

Planner Planner 4.5.5.1 From WOs raised, Identify CM Tasks to be done from next week onwards 4.5.5.2 Field Inspection Yes Required?

Foreman CM 4.5.5.3 Do Field inspection: ID Spares, Support Equipment, People, Time required Complete Job/Task Instruction

4.5.1

4.5.15 Outage Planning

No

work done ays ng

Last week before outage Follow-up on Specific Material orders

Foreman CM

Sup CM

4.5.5.4 Material / services Required?

Yes

4.5.5.5 Approve Quantities?

No

No

Yes

Planner MIMS

DM M

4.5.5.6 Complete Material / Services Requisition

4.5 App Requ

Plan

ner 4.5.8 additional tasks (planning mpleted) to be e during Forced Outage

Planner 4.5.9 Negotiate outage time & duration with Ops Planner & Dispatcher.

Planner MIMS

ing ks

on

4.5.11 Upload schedule into MIMS

Planning Sup Planner Printer 4.5.13 Print Job Cards

4.5.14 Distribute Job Cards

Planner

Foreman CM 4.5.5.3 Do Field inspection: ID Spares, Support Equipment, People, Time required Complete Job/Task Instruction

4.5.5.2 Inspection Yes equired?

No

up CM

4.5.5.5 Approve uantities?

No Planner

Yes

Planner MIMS

DM Maint. MIMS 4.5.5.8 Requisition Approved?

No

4.5.5.6 Complete Material / Services Requisition

4.5.5.7 Approve Requisition Planner

Yes

Planner 4.5.5.9 All required Material & services Available? Yes No 4.5.5.10 Initiate Procurement Process

4.5.7

4.0 Planning & Scheduling

Planner (Ops & Maint) 4.1.1 Obtain planning inputs Current 5 year plan Planned Outages per unit Operational Plan - 5 year production plan (Dispatchers) History (Forced & Maint. Outages) Unit Capacities Major Modifications / Upgrades Other major events to be planned for Fuel Supply Safety Insurance Environment Planner (Ops & Maint) 4.1.2 Prepare a draft 5-year plan Draft Schedule Resource Requirements Identify Long Lead Items & Services 4.1.3 Distribute draft Plan Ops Planner UP Planning Team 4.1.4 Yearly Planning Meeting no 1 UP Manager DMs Ops Planner Maint. Planner

Planner (Ops & Maint)

4.1.5 Update 5-year p as per minutes meeting

UP Manager

4.1.6 Distribute Plan PJB Planning Team 4.1.7 Yearly Planning Meeting no 2: Approve 5-year Plan ROP PJB UP Manager DMs PJB Budgeting, Financing & Corporate Planner Direktorat Niaga Planner (Ops & Maint) 4.1.8 Update 5-year plan as per minutes of meeting 4.1.9 Distribute Approved Plan ROP PJB UP Manager DMs Ops Planner Maint. Planner PJB Corporate Planner Direktorat Niaga Maint. Planner 4.1.11 Place orders for long lead items (Specific Material) UP Manager Planner (Ops & Maint) 4.1.10 Place Schedule onto notice boards in planning offices

nning Team

Planner (Ops & Maint) 4.1.5 Update 5-year plan as per minutes of meeting

Planner 4.2.1 Plot 52-week Calender

Planner 4.2.2 Indicate Planned Outages / Projects (from 5-year plan)

Planner 4.2.3 List ALL Scheduled Tasks

4.1.4 y Planning ting no 1

Manager s Planner nt. Planner

Planner 4.2.5 Determine Available Labour hours / Workgroup / skill level / week

Planner

4.2.6 Identify Imbala

anager

Planner (Ops & Maint) 4.1.10 Place Schedule onto notice boards in planning offices

Corrective Maintenance (CM, UHAR, Contractor)

Planner 4.2.8 Allocate Estimated Duration / Workgroup / skill level / week

1.9 Approved an Maint. Planner 4.1.11 Place orders for long lead items (Specific Material)

Planner 4.2.9 Determine Required Spares & Tools

Planner 4.2.10 Compile Maintenance & Capital Budget

Team 4.2.11 Review Meeting DM Maintenance Supervisors PM Supervisor PdM Supervisors CM Maintenance foremen Maintenance Planners Ops Supervisor Ops Planner

Plan

PJB anager

Upd

lanner Planner orporate er orat

Planner

Planner 4.3.2 Identify Major Projects to be executed within next Quarter

Outage Team

Planner 4.2.3 List ALL Scheduled Tasks

Planner 4.2.4 Allocate Estimated Duration / Workgroup / skill level / week

4.3.1 Identify Outages to be executed within next Quarter

Planner 4.2.5 Determine Available Labour hours / Workgroup / skill level / week

Planner 4.2.6 Identify Imbalances

Planner

4.2.7 Address Imbalances

Scheduled Maintenance (PM & Planned Outages)

4.3.3 Meeting 1 Confirm Outages & Projects for next Quarter

3 Months prior to outage / Project

Planner 4.3.7 Identify ALL Specific Material required.

Planner 4.3.8 Specific Material Available? Yes No

Planner 4.3.11 Prioritise tasks to be carried out during outage.

Outage Team 4.3.12 Meeting 2 Review / refine scope / priority & Specific Material 2 Months prior to outage / Project

Planner

4.3. Update s work & S Materia mee

Team 4.2.11 Review Meeting DM Maintenance Supervisors PM Supervisor PdM Supervisors CM Maintenance foremen Maintenance Planners Ops Supervisor Ops Planner

Planner 4.2.12 Update Plan of the Year

Planner MIMS

UHAR 4.3.16 Plan all tasks (HR, Spares, tools, Support Eq)

UHAR 4.3.17 Prepare Overhaul schedule

Outage Te

4.3. Meeti Approve O Plan & S 1 Month outage /

4.2.13 Update MIMS Maint. Planner 4.2.14 Place order for long lead items (3 months plus)
Planner MIMS DM Maint. MIMS

Planner MIMS

4.3.20 Upload to MIMS & Create WOs Parent, Sub, Standing

4.3.21 Approve Work Orders

4.3.22 Issue requisit Specific Spa

To be completed within One Week after Mee

First Line Maintenance

Planner 4.3.25 Get Feedback on Current Standing Work Order for Closure

Planner

4.3.26 Do Job Feedba on Current Standing Wor Order

anner

Outage Team 4.3.3 Meeting 1 Confirm Outages & Projects for next Quarter 3 Months prior to outage / Project

Planner 4.3.4 Prepare Standard Scope of Work

4.3.2 Identify Major Projects to be executed within next Quarter

Planner 4.3.5 Identify additional scope of work (From PdM, PM, Incident Logs, UHAR)

Planner MIMS
12.5 WCO Planner

Mondays

4.3.6 Create WOs where necessary

MIMS

Planner 4.3.8 Specific Material Available? Yes No

Planner 4.3.9 Initiate Purchase Procedure

Planner 4.3.10 Identify tasks where material will not be available for Outage / Project

4.4.1 Extract list of work orders to be started from next week onwards

Outage Team 4.3.12 Meeting 2 Review / refine scope / priority & Specific Material 2 Months prior to outage / Project UHAR 4.3.17 Prepare Overhaul schedule

Planner 4.3.13 Update scope of work & Specific Material from meeting

DM Maint. & UHAR 4.3.14 Approve minutes & final scope of work & Specific Material

Planner 4.3.15 Distribute Scope of Work to Planner UP & UHAR

Mondays to Wednesdays

Outage Team 4.3.18 Meeting 3 Approve Overhaul Plan & Schedule 1 Month prior to outage / Project

Planner 4.3.19 Distribute schedule to Ops Sup, Maint. Sups & Foreman & UHAR

Plan the Jobs The purpose is to make sure that all the material and resources (Spares, Support Equipment, People, Time required to complete a Job) are available, complete with the detailed task instructions, BEFORE scheduling a job and issuing the jobcard. This will result in more effective use of limited and valuable maintenance manhours by reducing wasted maintenance manhours through preventing starting a job and then have to wait for material and other resources.

Pr M

Week Additio

C M

WOs WOs PdMs

10

Rep

DM Maint. MIMS

Planner MIMS

DM Maint. MIMS

Planner Printer 4.3.24 Print Job Cards

WOs WOs PdMs

4.3.21 Approve Work Orders

4.3.22 Issue requisitions Specific Spares

4.3.23 Approve Requisitions

R Contr

o be completed within One Week after Meeting 3

WOs WOs PdMs

anner

Planner 4.3.26 Do Job Feedback on Current Standing Work Order

Planner 4.3.27 Close Current Standing Work Order

Planner 4.3.28 Raise New Standing Work Order

4.3.25 Get Feedback on Current Standing Work Order for Closure

Fridays

Thursdays

Fridays

12.5 WCO Planner MIMS 4.4.19 Outage Planning

Mondays

4.4.1 Extract list of work orders to be started from next week onwards

Follow-up on Specific Material orders

Mondays to Wednesdays

Plan the Jobs The purpose is to make sure that all the material and resources (Spares, Support Equipment, People, Time required to complete a Job) are available, complete with the detailed task instructions, BEFORE scheduling a job and issuing the jobcard. This will result in more effective use of limited and valuable maintenance manhours by reducing wasted maintenance manhours through preventing starting a job and then have to wait for material and other resources.

4.4.2 Preventative Maintenance Planning Weekly list of standard PMs Additional PMs required

Planner 4.4.6 Is an outage Yes (maint./ planned) required to do a job? No Maint. Outage

Planner Planner 4.4.7 Can it be postponed till next planned outage? No Planner 4.4.10 Negotiate outage time & duration with Ops Planner & Dispatcher.

4.4.3 Corrective Maintenance Planning WOs from reported faults WOs resulting from PMs and PdMs 4.4.4 Repair by UHAR Planning

Yes

4.4.8 Update task detail & Mark WO for next Planned Outage

4.3.4

Planner 4.4.9 ID additional tasks (planning completed) to be done during Maint. Outage Opportunity

WOs from reported faults WOs resulting from PMs and PdMs 4.4.5 Repair by Contractor Planning

Planner 4.4.11 Complete Planning & Schedule tasks for next week Do resource smoothing Job Description

Planner MIMS

Planner Printer 4.4.13 Print Job Lists for next week for review meeting

WOs from reported faults WOs resulting from PMs and PdMs Weekly Review Team

4.4.12 Upload schedule into MIMS

Planner 4.4.15 Update & Finalise Schedules

Planning Sup MIMS

Thursdays

4.4.14 Weekly Review Meeting Schedule Backlog DM Maint Planning Sup Planners CM Sups PM Sups PdM Sups Ops Planning Supervisor

Planner Printer 4.4.17 Print Job Cards PdM Job List

4.4.16 Approve Work Orders

Planning Sup

Fridays

4.4.18 Distribute Job Cards & PdM Job List

 Ops Planning Supervisor

Fridays

4.4.18 Distribute Job Cards & PdM Job List

Planner 4.4.2.1 From MIMS, Identify Standard PM Tasks for next week Planner 4.4.2.3 From WOs raised, Identify PM Tasks to be done during next week

Planner MIMS

4.4.1

4.4.6

4.4.2.2 Run weekly Planning process

fic Material

etail next age

4.3.4

age n with r& .

inter

4.13 b Lists for week for meeting

Printer

4.4.17 Job Cards M Job List

ing Sup

4.18 bute Job & PdM Job List

4.18 bute Job & PdM Job List

Planner Planner 4.4.3.1 From WOs raised, Identify CM Tasks to be done from next week onwards 4.4.3.2 Field Inspection Yes Required?

Foreman CM 4.4.3.3 Do Field inspection: ID Spares, Support Equipment, People, Time required Complete Job/Task Instructions

4.4.1

No

Foreman CM

Sup CM

4.4.3.4 Material / services Required?

Yes

4.4.3.5 Approve Quantities?

No Planner

No

Yes

Planner MIMS

DM Maint. MIMS 4.4.3.8 Requisition Approved?

No

4.4.3.6 Complete Material / Services Requisition

4.4.3.7 Approve Requisition Planner

Yes

Planner 4.4.3.9 All required Material & services Available? Yes No 4.4.3.10 Initiate Procurement Process

4.4.6

4.4.1

Planner 4.4.4.1 From WOs raised, Identify UHAR Tasks to be done from next week onwards

Planner 4.4.4.2 Notify UHAR

UHAR 4.4.4.3 Field Inspection Required? No

UHAR 4.4.4.4 Do Field inspection: ID Spares, Support Equipment, People, Time required Complete Job/Task Instructions

Yes

UHAR 4.4.4.5 Material / services Required? No

UHAR 4.4.4.6 Approve Quantities? Yes Planner Planner UP / UHAR MIMS DM Maint. UP / Man. UHAR MIMS 4.4.4.9 Requisition Approved?

Yes

No

anner

4.4.3.8 Requisition Approved?

No

Yes
4.4.4.7 Complete General / Specific Material Requisition 4.4.4.8 Approve Requisition

No

Yes

Planner 4.4.3.10 Initiate Procurement Process

Planner Planner 4.4.4.10 Material Available? No 4.4.4.11 Initiate Procurement Process

4.4.6
Yes UHAR 4.4.4.12 Prepare & Submit Quotation Scope, Schedule Time required Cost

AR

4.4.4.4 Field inspection: Spares, Support pment, People, ime required mplete Job/Task Instructions

4.4.1

Planner 4.4.5.1 From WOs raised, Identify Contractor Tasks to be done from next week onwards

Planner 4.4.5.2 Compile specification for work to be done

Planner 4.4.5.3 Initiate procurement process (incl. service)

Planner & Procurem

4.4 Review O Cont

Planner

UP / R 4.4.4.9 Requisition Approved?

No

8 ve ion

Yes

Planner Planner 4.4.4.10 Material Available? No 4.4.4.11 Initiate Procurement Process

Yes UHAR 4.4.4.12 Prepare & Submit Quotation Scope, Schedule Time required Cost

4.4.6

Planner 4.4.5.3 Initiate procurement process (incl. service)

Planner & Procurement 4.4.5.4 Review Offers from Contractors 4.4.6

5.0 Operator Cheks for Maintenance

Ops & Maint Planner Ops Planner 5.2 File Check Lists & copy 3-month stock 5.1 Compile check lists from OEM Manuals, As Built & Maint Requirements 5.3 Collect Check list from Ops Planner Operator Operator 5.4 Perform check list inspections twice per shift Operator 5.5 Problem identified? Yes

1.1 FR

No

Supervisor Ops 5.6 Check & approve

Supervisor Ops

Ops Planner 5.8 Prepare monthly report (plant / equipment efficiency)

Ops Planner 5.9 Problem identified from trend? Yes No

Ops Planner 5.10 Archive Check Lists

5.7 Return Check List to Ops Planner

1.13 FR

13.3

7.0 Predictive Maintenance

Sup PDM Sup PDM 7.2 Plan and schedule daily tasks 7.1 Collects Weekly Schedule from Planning Sup PDM 7.3 Issue daily task lists to Technicians

Tech PDM Tech PDM 7.4 Prepare Tools for PDM 7.5 Yes Require Permit to Work? Tech PDM 7.6 Obtain Permit to Work from Sup Ops Tech PDM 7.7 Execute work Daily No Tech

Down & pr

Sup PDM Sup PDM 7.9 Evaluate Daily Reports and compile weekly report Daily No 7.10 ID Problems that require further attention? Daily Yes Sup PDM 7.11 Inform Planner Daily Sup PDM

7.12 File the analysis report

.3 y task lists hnicians

Tech PDM 7.7 Execute work Daily

Tech PDM 7.8 Download, Analyse & produce report Daily

11 Planner

4 P&S

aily Sup PDM 7.12 File the analysis report

End

8.0 Repair Uhar

To be authorised by HO
UHAR to raise requisition for: Consumables General Material Specific spares (to be authorised by UP Planner

Sup

3.5 EM

C rea

Planner UHAR 4 P&S 8.1 Receive Job Card from UP Planner UHAR 8.4 Obtain Permit to Work UHAR 8.2 Plan & schedule work to be done 8.3 Repair Work to be done on-site? No UHAR 8.5 Execute Work Request material Purchase non-stock

Yes

UHAR UHAR 8.7 Work specified Yes on job card completed? 8.8 Sign-off Job Card UHAR 8.9 Require additional work? Yes No UHAR 8.12 Get UP Planner to Coordinate between Ops & UHAR for test

No

UHAR Sen.Sup QA 8.11 Notify UP Planner that additional work is required before handing back. Yes 8.10 Must work be done before return to service?

No

UHAR 8.15 Close Permit to Work

UHAR 8.16 Hand back to Operations

UHAR

Planner / DM Maint UP 8.18 Acceptance Letter

8.17 Hand Job Card to Planner

UHAR 8.15 Close Permit to Work

UHAR 8.16 Hand back to Operations

UHAR

Planner / DM Maint UP 8.18 Acceptance Letter

8.17 Hand Job Card to Planner

Sup Ops 8.14 Capture rework reason on job card

UHAR 8.5 Execute Work Request material Purchase non-stock

UHAR 8.6 Capture Job Feedback

UHAR 8.12 Get UP Planner to Coordinate between Ops & UHAR for test

Sup Ops 8.13 Test & Accept work? Yes

No

No

UHAR

Planner / DM Maint UP 8.18 Acceptance Letter 12.1 CWO

8.17 and Job Card to Planner

UHAR

Planner / DM Maint UP 8.18 Acceptance Letter 12.1 CWO

8.17 and Job Card to Planner

9.0 Repair Contractor

Contractor Contractor Contractor 9.2 Plan & Schedule work 9.1 Receive Purchase Order Contractor 9.3 Notify UP Planner when you will start 9.4 Work to be done on site? Yes Contractor 9.5 Obtain Permit to Work

No

Contractor 9.8 Planner to Coordinate between Ops & Contractor for test

Contractor 9.7 Capture Job Feedback

Contra

R Pu

Sup Ops No 9.9 Test & Accept work? Yes

UP QC Team 9.10 Acceptance Letter

Contractor 9.11 Close Permit to Work

Contractor 9.12 Hand back to Operations Contractor

9.13 Hand Job Feedba Planner

Requisition Process (inside 9.6)

Contractor Planner UP MIMS DM Maint UP 9.6.3 Approve Requisition? No Planner UP 9.6.4 Notify Contractor that Spares Requisition is not approved

9.6.1 9.6.2 Give Spares List to UP Raise Material Planner for requisition Requisition

Yes

Planner UP 9.6.5 Notify Contractor that Spares Requisition is approved

Contractor 9.6.6 Draw spares from UP store

Sup Maint UHAR 9.6.7 Spares available? No

Contractor 9.6.8 Contractor to purchase spares

Yes

9.6

ctor Contractor Yes 9.5 Obtain Permit to Work

9.4 ork to be e on site?

No

Contractor 9.7 Capture Job Feedback

Contractor 9.6 Execute Work Request material Purchase non-stock

tractor

9.12 Hand back to Operations Contractor 12.1 CWO 9.13 Hand Job Feedback to Planner

.6)

UP

9.6.4 Contractor Spares ition is not proved

R No

Contractor 9.6.8 Contractor to purchase spares

9.6

10.0 Overhaul
Sup OH Maint Planner
ELLIPSE

DM Maint
ELLIPSE

Planner 10.4 Material Available? No

Planner

10. Follow Pu Proce

10.1 Received Job Card from Planner

10.2 Issue requisition General Material, Consumables

10.3 Approve requisition

Tech OH Maint 10.8 Obtain Permit to Work

Supervisor Ops 10.6 Shutdown Unit/ equipments

Supervisor Ops 10.7 Handover to start up Team

Tech OH M Contractor

Tech OH Maint 10.9 Prepares tools and get spares

10.1 Execute

Planner 10.11 Additional work required No

Sup OH Maint 10.12 Identify & scope the additional work required

DM Maint 10.13 Get Approval

No DM Maint 10.14 Required in shutdown No Planner 10.15 Issue approval note Planner
ELLIPSE

Planner

Yes

Prin

10.16 Create WO Planner MIMS Start-up Team 10.21 Test Acceptance

10.1 Print Jo

4.0

Tech OH Maint/ Contractor 10.19 Capture Job feedback on Job Cards

Sup OH Maint 10.20 Evaluate & Approved result of work

10.18 Create WO

Start-up Team No Tech OH Maint 10.22 Close Permit to Work with Start Up Team Sup OH Maint Sup OH Maint 10.25 Compile Overhaul report 10.23 Start up plant

Pla

R R

10.26 Return job card & report to Planner

Close Permit to Work with Start Up Team Sup OH Maint Sup OH Maint 10.25 Compile Overhaul report

Pla

R R

10.26 Return job card & report to Planner

Planner 10.4 Material Available? No

Planner 10.5 Follow Purchase Procedure

Maint

.8 Permit to ork

Tech OH Maint/ Contractor/ Eng 10.10 Execute Work

Maint

.9 tools and pares

Planner
ELLIPSE

Planner Printer 10.17 Print Job Card

10.16 Create WO Planner MIMS

4.0

10.18 Create WO

Start-up Team 10.23 Start up plant

Start-up Team 10.24 Hand back to OPS Issue hand over certificate

aint

2 mit to Start Up m Sup OH Maint Planner

nt

5 verhaul t

10.27 Review overhaul Report to identify improvement opportunities 10.26 Return job card & report to Planner

12.1 CWO

mit to Start Up m Sup OH Maint Planner 10.27 Review overhaul Report to identify improvement opportunities 10.26 Return job card & report to Planner 12.1 CWO

nt

5 verhaul t

11.0 Corrective Maintenance

Tech CR Maint Sup CR Tech Cr Maint 11.2 Obtain Material / spares / tools 11.1 Collect Job Card 11.3 Spares / Resources Available? No Tech CR Maint MIMS 11.5 Notify Sup Ops & Sup CR Maint Tech CR Maint Tech

Stage Sp Res

Yes

11.4 Update Job Status Awaiting Spares

Tech Cr Maint 11.7 Permit to Work? Yes

Tech Cr Maint 11.8 Get Permit to Work from Supervisor Ops

Tech Cr Maint 11.9 Perform required Maint. Job

Tech C

Reco (fai corre mater WO retur

No

DM Maint Yes 11.15 Approve Requisition?

Sup CR Yes 11.14 Approve Quantities etc.? No

Foreman MIMS

Tech Cr No Maint Yes 11.12 Additional Material? No

Su

Work on com

No

11.13 Material & Spares Requisition MSQ140 / MSQ Action I

Sup CR Sup CR 11.18 Notify UP Planner that additional work is required before handing back. Yes 11.17 Must work be done before return to service? No Sup CR 11.19 Capture Additional work required on Job Card Yes

Sup CR 11.16 Require additional work? No Sup Ops 11.20 Test & Accept work? Yes

Postpone

Sup O

No

Cap reaso

Tech Cr Maint 11.22 Return unused material / spares

Tech Cr Maint 11.23 Close Permit to Work

Foreman 11.24 Sign-off Job Card

Foreman 11.25 Hand back to Operations

Sup CR

11.26

Yes Tech Cr Maint 11.22 Return unused material / spares Tech Cr Maint 11.23 Close Permit to Work Foreman 11.24 Sign-off Job Card Foreman 11.25 Hand back to Operations

Sup CR

11.26 Hand Job Ca Planner

Tech CR Maint

Tech CR Maint 11.6 Stage & Source Spares / Resources.

us s

11.5 Notify Sup Ops & Sup CR Maint

Tech Cr Maint 11.9 Perform required Maint. Job

Tech Cr Maint 11.10 Record all findings (failure, cause, corrective action, material usage) on WO / workbook & return to Ops Sup

No

Sup CR

12 onal rial?

No

11.11 Work specified on job card completed?

Yes

CR

16 uire onal rk?

No Sup Ops 11.20 Test & Accept work? Yes Foreman 11.25 Hand back to Operations 11.26 Sup CR 12.1 CWO Sup Ops 11.21 Capture rework reason on job card

No

Yes Foreman 11.25 Hand back to Operations 11.26 Hand Job Card to Planner Sup CR 12.1 CWO

12.0 Close WO
3.22 EM Planner 6.16 PM 12.1 Receive completed Job Cards

8.18 UHAR

Planner Planner MIMS Planner MIMS 12.4 Are there Yes any identified Problems to be fixed? No

Plan

9.13 Contr

10.27 Ovrh

12.2 Capture Job Feedback on MIMS

12.3 Close Work Orders Standing Sub Main

Cre Ord ap

11.26 CR

End

Planner Planner 12.4 Are there Yes any identified Problems to be fixed? No MIMS

4.4.1 P&S 4.5.3 P&S

12.5 Create new Work Order Assign to applicable work group

13.2

End

13.0 Identify Maintenance Improvement Opportunities

Planner 13.1 Identify Deteriorating Reliabilities

2.9 FLM 12.5 WCO

Planner 13.2 Identify Deteriorating Availabilities

Planner 13.4 Raise Maintenance Improvement ECP as per 17.2

Ops Planner 5.8 OC 13.3 Identify Low or Deteriorating Efficiencies Same as 17.2, just more specific for Maintenance Improvement Opportunities

Same as 17.1, just in more detail for Maintenance Improvement Opportunities

ment Opportunities

anner

13.4 aise Maintenance mprovement ECP as per 17.2

17.3

me as 17.2, just more cific for Maintenance Improvement Opportunities

17.0 Engineering Change Management

Originator 17.1 Identify need for change / modification Originator 17.2 Complete change proposal form (ECP) Originator 17.3 Submit change proposal to your Supervisor Supervisor 17.4 Evaluate proposed change (Approve) Change Management Team 17.5 Safety Evaluate proposed Process change Improvement (Weekly Meeting) Availability Reliability etc

See 13 for Maintenance Improvement Opportunities

Deputy Manager Eng 17.6 Accept need to change? No

Deputy Manager Eng 17.7 Notify Originator

Deputy Manager Eng 17.8 Archive ECP

Yes

See 14.1 14.3 for Maintenance Improvement Opportunities

Eng Team 17.9 Finalise / design the change / modification package Eng Team 17.10 Indicate on ECP what docs. & systems needs to be updated Planner (Ops / Maint) 17.11 Plan Implementation Eng 17.16 Supply Updated Drawings Eng 17.17 Ops Manual Eng 17.18 SOP Eng Ops / UHAR / Contractor / CM 17.14 Implement Change / Modification Eng 17.15 Update package to As Built 17.19 Maint Manual Eng 17.20 Update PdM Schedules Eng Planner Maint MIMS 17.21 Update PM Schedules Eng 17.22 Update MIMS (Equipment) Eng 17.23 Update Process Control System Eng 17.24 Update Business Process Deputy Manager Eng 17.25 Sign Off ECP See 14.4 14.8 for Maintenance Improvement Opportunities

Eng Team No 17.12 Require WO?

Yes

Deputy Manager

17.26 Archive ECP

17.13 Issue Work Order

anagement
Change Management Team 17.5 Safety Evaluate proposed Process change Improvement (Weekly Meeting) Availability Reliability etc

ed

Deputy Manager Eng 17.25 Sign Off ECP

Deputy Manager Eng 17.26 Archive ECP

ss m

ss

14.0 Maintenance Optimisation

Engineer 17.5 ECM 14.1 Receive approved Maint Improvement ECPs Engineer 14.2 Investigate Proposals RCFA FMEA Estimate Cost Benefit Spare Parts Reliability Availability Efficiency Safety Production Environment Process Etc. Same as 17.6, just in more detail for Maintenance Improvement Opportunities Eng Coordinator No

14.3 Go Ahead?

17.7 ECM

Yes

Eng Coordinator Engineer 14.4 Prioritise Proposals for Design Use same process as SERP Engineer 14.5 Design Solution FDT Process Stock Levels Procedure Documentation Etc. Planner 14.6 Determine final Costs and benefit of designed solution 14.7 Approve designed solution? Yes Engineer 14.8 Prioritise Implementations Implementation Schedule

17 EC

No

Same as 17.9, just in more detail for Maintenance Improvement Opportunities

misation

17.7 ECM

or Engineer Yes 14.8 Prioritise Implementations Implementation Schedule 17.10 ECM

nities