Maintenance Planner

Westeel - Winnipeg, MB
Position Summary:

The role of the Maintenance Planner is to improve work force productivity and quality by
anticipating and eliminating potential delays through planning, scheduling, and coordination of
maintenance resources, parts, materials, and equipment access. This role reports to the
Facilities Manager. Responsibilities include planning and coordination of all planned
maintenance activities performed at the site.

The Maintenance Planner is responsible for working with maintenance and operations personnel
to plan, schedule and track routine and regular preventative maintenance for critical production
equipment. The Maintenance Planner also works closely with managers in other departments
and with outside resources to deliver long-term planned maintenance outcomes.

Key Responsibilities and Accountabilities:

 Planning responsibilities include; researching, scoping of work, estimating material and

labour requirements, developing task instructions, identifying tool and equipment
requirements, and developing a list of materials for the work.
 Evaluate, create, and/or implement preventative and predictive maintenance tasks for
existing and new equipment
 Work alongside Maintenance Clerk and Maintenance Lead Hand to ensure correct parts
and equipment are ordered in a timely manner.
 Create purchasing requirements for planned work as needed.
 Research and scope job requirements
 Arrange for the necessary parts, equipment, services and information to be prepared and
available for all preventative maintenance activities
 Develop job lists and provide detailed instructions needed to execute jobsAssisting in
kitting and staging of job materials for Millwrights and Electricians for planned work.
 Collaborate with supervisors and managers in all departments to plan, schedule and
implement preventative maintenance activities
 Communicate with OEM and outside contractors
 Plan and schedule major shutdowns.
 Track, record and document preventative maintenance activities, and maintain accurate
records of such activities for reference and for future planning purposes
 Participate in the root cause analysis process to solve equipment maintenance issues
 Review existing and new equipment critical spare parts requirement.
 Make necessary adjustment in CMMS system to reflect requirements
 Review and update equipment file, documentation, and drawings/ schematics
 Keep Facilities Manager informed of abnormal or critical situations and seeks advice on
matters outside the Planner’s knowledge or authority.
 Assist in costing analysis and budgetary activities
 Other duties as assigned

Knowledge and Skill Requirements:

Education and Experience

 College education in Electrical, Instrumentation, Millwright, Mechanical Engineering or

other related post-secondary an asset.
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  Minimum of five years of experience in an industrial maintenance setting

Skill

 Thorough knowledge of production, maintenance and planning processes.

 Proficiency in all Microsoft Office products, especially MS Access and Excel
 Experience in a metal manufacturing industry an asset
 Previous work with TPM is preferred
 Excellent organization skills
 Excellent communication Skills
 Ability to work independently
 Awareness of relevant government regulations.
 Working knowledge of SAP is an asset
 Team Player

Job Type: Full-time

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MAINTENANCE:
Maintenance may be defined as the chronological activities or as the process of systematic activities done
for keeping the m\c or equipments at the heat level for well run or its proper services.

AIMS of MAINTENANCE:

1. To maintain m\c equipment at optimum operation speed & production efficiency

2. To unsure best possible level of quality of product.
3. To minimize the idle time resulting from the machinery break down.
4. To reduce the cost.

IMPORTANCE of MAINTENANCE:

1. To increase the life time cycle of machinery & equipment

2. In case of appropriate functioning.
3. Better or superior quality for the product.
4. Higher productivity of machines
5. Wastage reduces & control.
6. Economization of the process.

EFFECTS of MAINTENANCE:

1. Due to proper maintenance reduce undue worn out of different parts & equipment as well as corrosion
of the items & increase the machines life ( these are the result of routine cleaning, lubricating,
repairing, replacement, fitting, & refitting etc.)
2. For sound or congenial operation of machinery, it is required the proper lubrication, fitting, repairing,
& replacement (as per necessity).
3. By the continuous operation of the machinery reduces stoppages time resulting better quality & less
wastage

OPERATION INVOLVED in MAINTENANCE:

Setting: Setting is the activities to set or install the machine parts or required ancillaries. Adjustment also
complementary word to setting used for appropriate setting.

Checking: Checking means investigation of machine condition. It is very important work in case of
maintenance. It is very skilled depends work as successful maintenance that depends on correct fault
detection.

Repairing: Repairing or altering of spares & equipment (if necessary) is to be detected & necessary
measures are taken (repairing\altering\setting\adjustment) .

Overhauling: It is the work of maintenance, but not frequent or schedule work. It is done as per as
necessary.

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SYSTEM of MAINTENANCE:
Basically there exist 2 systems on which based different types of maintenance are done. They are:

1. Break down maintenance

2. Planned maintenance.
TYPES of MAINTENANCE:

1. Preventive maintenance.
2. Productive maintenance.
3. Routine\schedule maintenance. (cleaning,checking, lubricating)
4. Remedial maintenance.
5. Restorative maintenance\emergency maintenance.
POWER TRANSMISSION:
Power may be transmitted in the following ways. They are:

1. By mechanical means
2. By electrical means
3. By electro-mechanical means
4. By hydraulic means
5. Others (aeronautics)
In them the mechanical means transmission is classified in following

Through belt & pulley (Flat belt & flat pulley)

 (V-belt& V-pulley)
 (Timing belt & Timing pulley)
Through gears (Straight gears such as Spur gearing)

 (Epicyclical gearings)
Through chain-sprocket

LUBRICANTS:
2 types of lubricant on the basis of viscosity

1. Oil
2. Grease
For evaluating lubricant following factors are considered

1. Sp. gravity
2. Viscosity
3. Flash point
4. Pour point
5. CST (cent stroke behavior at 400c both for oil & grease)
EFFECT of LUBRUCANT:

1. Corrosion (anti corrosion effectiveness)

2. Uniformity & optimum speed attainment
3. Recommended legibility of the spares & parts
4. High efficiency (due to low break down stoppage of the material)
5. Higher quality of the product
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 6. Low work load on the work arm
7. Less material handling
SYSTEM & PROCEDURE of MAINTENANCE:

1. For effective maintenance a no. of pre-requirement site have to met

2. There must be a well defined organizational structure to & implement the program.
3. Proper planning, scheduling & controlling of maintenance must be designed.
4. An appropriate flow of information & data on maintenance must be devised.
5. Timely supply of the spare parts & also other materials needed must be ensured.
6. Personnel of varying skilled & competence must be engaged.
WHAT ARE THE SYSTEM & PROCEDURE of MAINTENANCE?
The answer will depend on the aspects emphasized. It may be of two natures:

1. Management aspects
2. Technical aspects
In managerial aspects, system may be defined as the means which the personnel of an enterprise operate to
accomplish the enterprise objects. They provide the means of translating managerial policies. Procedure
will be that they are written & oral instruction which give formal sanction to a system. On the other hand
of stress is given to on technical works & parameters than a system may be considered a network of related
production developed according to an integrated scheme for performing a major activity or function.
Procedure may be regarded as a sequence of technical operation established to ensure uniform
accomplishment of recurring tasks.

NECESSITY of SYSTEM & PROCEDURE:

Maintenance operations are characteristics by wide range & different degree of uncertainty. Those have to
done by the people of varying skills. Some jobs are cyclic tasks some are not. Even in the case of cyclic
tasks, the interval between the 2 constructive operational ranges quite widely from once week to all most
twice a year. Also there are a few works which are alternatively overlapping. In some causes execution of
certain the task is automatically implies carrying out of certain other tasks also.

SCHEMATIC DIAGRAM of MAINTENANCE ACTIVITIES DEPENDING on THEIR

UNCERTAINITY LEVEL:

There the things are shown below:

Repetitive:
1. Routine maintenance
2. Preventive maintenance
3. Statuary maintenance
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Non-repetitive:
1. Major repairing
2. Erective maintenance
3. Re-erective maintenance
4. Overhauling maintenance
Unknown:

1. Corrective action to be taken on the basis of the preventive maintenance.

2. Emergency maintenance
3. Re-storative maintenance
4. Change of lay out.
STEPS of MAINTENANCE:
The steps of maintenance are:
1. Planning
2. Scheduling
3. Controlling
Planning:
Controllable work is considered as a planning. Since a comprehensive maintenance analysis is needed for
the purpose. It is usable to cover a time spam of one year.

1. Basically the decision to be taken in the 1st 2 stapes of planning are more oh technical in nature then
administration. It sufficient to make the following brief remarkable to indicate. The range of decision to be
taken at planning stages.

2. The frequency cleaning needed to be established with reference to degree of dirt & fly accumulation.

3. lubrication cycle are laid down taking into account bearing design & operating speed, the re-
commendation of the different oil companies may be as guide in the content.

4. The frequencies & kind of routines maintenance operation are fixed with regarding the machinery
manufacturing & the recommending rate of the wear precession & accuracy of settings, adjustment, loss in
efficiency process faults machinery break down & above the all past experience to related matters.

5. Details of preventive maintenance program suited for the particular condition the mills are finalized after
taking into amount such as no of machines & types of the skilled technician’s available tools & aids are in
the disposal, necessary check the lists are also developed for preventive maintenance.

6. Re-storative maintenance plans like likely to neutralized during the year ahead are also taken note of.
Most of the data for the steps have to be gathered from the equipment history records. If such records are
not available in the mills they must be 1st made from purchase envious. Manufacturing manual & leaflets
are before analysis. Additional data required can be had from production, costing & quality
controls departments.

Factors should be considered & stressed during planning & maintenance:

1) Timing (on over time or least over timing is considered)

2) Skill of man power
3) Relevancy
4) Costing.

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SCHEDULING:
Planning has defined as the various maintenance tasks to be carried out on the each machines during the
course of year. Scheduling is the process of getting RIGHT man & facilities with RIGHT time & the
RIGHT place in scheduling comprises the process of 3R’s.

Advantages:
1) Minimize the delays arising from the lacks of the co-ordinates between production & maintenance
schedule.
2) Reduce the loss of useful man hours because of unnecessary walking tines & material handling.
3) Co-ordinates multi skilled jobs to optimize the skills utilization consistent with minimum m/c down
time.
4) Operative idle time is minimized.
5) Co ordinates with SQC to ascertain the effectiveness of the maintenance operation & their adequacy.

Scheduling Component:
1) Work unit
2) Size of the jobs
3) Man- hour scheduling in relation with the total man hour available.
4) Lead time for scheduling.

CONTROLLING:
All planning & scheduling without effective control & the means of enforcing then would be unless &
waste of time & efforts. The aims of maintenance control are given below:

1. To provide mgt with the tools, that will disclose deviation from Plane & schedules so that back logs
can deal with
2. To provide the feedback information from preventive maintenance. Check the lists & diagnostic report
signaling.
3. The need not only for the remedial maintenance but for reviewing the various scheduling established
in the annual plans.
4. The information for the QC & costing department will also the supplementary sources & feedback.
RECORDS FOR THE EFFECTIVE MAINTENANCE CONTROLLING:

1) Maintenance ledger
2) M/c cards
3) Job in complete report
4) Lubricant control chart
5) Over time requisition form
6) Weekly work order sheet
7) Maintenance chart
8) Mechanical down time
9) Break-down time
10) Over time engagement record
11) Monthly spares & lubricant consumptions.

ELEMENTS of MAINTENANCE:

1) Inspection / check up

 (External – sound, noise, vibration,)

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 (Internal – spare parts, shafts, motors & other mechanical & electrical installation)
2) Lubrication – Is the application of lubricant in the machinery during operation / break down.
Application of lubricant is governed by 4R’s. Such as

 Right types of lubricants

 Right place
 Right tune
 Right quality
(Note: High moving parts – oil; Low moving parts – grease)

3) Planning & scheduling – Every preventive maintenance or work is pre-planned. A routine is made for
maintenance & by scheduling it is followed strictly.

4) Training – Training is the essential the works fours of maintenance. It increases the skillness of man
power & effect the cost of production by enhancing the productivity, quality & machine legibility.

5) Recording & analysis – Work done & matter of maintenance should be properly recorded. Recording
is the very important for their maintenance guideline & trouble shooting. Remedial measures taken for a
particular trouble & its result during machine operation are also great importance for future schedule &
activities. Frequency of fault detection corrective measure etc analysis is the criterion for maintenance job.

STORAGE of SPARE PARTS:

1) Slow moving items (Available as per scheduling)
Fast moving items (Always available)
2) Lubricants should be available as per desired grade & amount.
3) Tools & equipments should also available in the maintenance department.

LUBRICANTS & LUBRICATION'S:

Lubricant is the organic compound higher molecular wt used in the m/c to protect corrosion & possibility
of failure. Lubrication is the process of application of lubricants in machinery during operation or
maintenance. Follow of 4R’s play vital role in congenial role of machine.

IMPORTANCE of LUBRICANT:

1. Reduction of wear & tear Reduces m/c maintenance time & cost.
2. Synchronized m/c operation appropriate rpm of m/c in optimal speed & uniformity of speed.
3. Legibility assurance of m/c & m/c parts.
4. Higher operating efficiency less idle time & stopping.
5. Better quality of products: due to well-running & disturbance are the causes of better quality products.
Reduces m/c stoppage frequency, so attainment of the higher quality.
6. Reduces fatigue & boredom of work forces due to well running less stoppage & troubles.
7. Develop ergonomics & improve working environment.
8. Above all maintenance, reduce work load & cost of overall manufacturing.
TYPES of LUBRICANT:
Lubricant can be classified broadly on their viscosity & sp viscosity

 Grease – higher viscosity & lower fluidity

 Oil – lower viscosity & higher fluidity
CHARACTERISTIC of LUBRICANT:

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 1. Viscosity
2. Sp. gravity
3. Flash point
4. Pour point
5. CST(Centistroke)
6. Volatility
7. Acid no of parts per million (ppm)
SELECTION of LUBRICANT:
Selection of lubricant is governed by following factors

1. Types of gear/bearing or point of lubricants

2. Speed of gears/shaft (in case of seal box of gear)
3. Reduction ratio
4. Operating temperature
5. Input horse power
6. Nature of load provided
The lubricant must reduce friction, prevent wear & tear on the corrosion & carry the load needed to keep
the m/c operation at higher efficiency level.

Furthermore the lubricant is required to maintain its physical characteristics & performance characteristics
for a long period of time without any degradation.

Recommendation of m/c manufacturer in the selection of lubricant & the frequency of lubricant are
important & to be taken as broad guide line.

Special consideration for the lubrication of the textile machinery:

 Maintain low power consumption

 Protection against corrosion
 Avoidance/safety from staining of product (yarn, fabric…etc)
FUNCTIONAL PROPERTIES of LUBRICANT:
Outcome from the physical properties

1. Lubricant must be resist oxidation

2. Lubricant must be resist carbon formation
3. Lubricant must be resist rust formation
4. Lubricant must anti-foaming
5. Lubricant must be resist extreme load
6. Lubricant must possess required viscosity
7. Lubricant must act goods cleaning agent (CCl4, petrol, diesel)
GEARS: Gears are toothed disc/pulley used for power transmission.

Kinds:

1. Straight gears/plain gears (used for power transfer at 1800 angle)

2. Helical gears (for avoiding slippage)
3. Bevel gears (for transfer at 900 angle)
4. Worm gear/wheel (for reduced power)
5. Sprocket wheel (straight transfer)
PULLEY: Plain disc which transmitted power by belt.
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BEARING: (Anti-friction element) it is an anti-friction element used to safe the rotary equipment from the
frictional element.

Kinds:
(On the basis of shape)

1. Ball bearing (Used in high speed terms)

2. Roller bearing (used large dimension terms)
3. Needle bearing (used in low speed terms)
According to lubrication facilities:

1. Open bearing (gradual lubricant)

2. Sealed bearing (no requirements of lubrication)
BUSH: Anti-friction arrangement used to safe the rotating shaft at very lower level rpm from corrosion.

PULLEY & BELT:

1. Flat pulley + Flat belt

2. Grooved pulley + V-belt
3. Toothed on timing pulley + Toothed belt (short distance & low speed)
4. Flange pulley + Flat belt
MAINTENANCE SCHEDULE:
Factor must be considered for maintenance schedule:

1. M/C type (mechanical, electrical, mechatronics basis)

2. Danger level/Risk level
3. Operational tenure (operational period round the clock/ shift basis/weekly/occasional)
4. Nature of the equipment
5. Availability of man power & skilled
6. Expenditure

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