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C501: Maintenance Shutdown and Project Management

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'Good maintenance project managers are both scarce and worth their weight in gold'

C501 7Maintenance abounds with projects, originating from the objective of high plant uptime. These include a seemingly perpetual stream of small and not so small improvement projects requested by production, as well as those deemed necessary by observation of failure trends.

Furthermore, the nature of the equipment being maintained often necessitates grouping preventive maintenance actions into shutdown occasions, varying from a weekly maintenance shift to extended maintenance occasions, ranging from a few days to a week or more. As lost production time is expensive, these events need to be managed closely using project management principles. It is consequently necessary to have a sound knowledge of the subject.

C501 6Short shutdown turnaround times are vital to profitability

Project and Shutdown Management embraces a variety of disciplines, including detailed project scheduling, task planning and control, purchasing control, cost control, and the ability to coordinate actions under highly pressurised circumstances.

The course in Shutdown and Project Management endeavours to provide the necessary theoretical foundation to equip maintenance people with the necessary skills to facilitate successful Maintenance Shutdowns and Project Management occasions. It is presented by a seasoned maintenance manager with extensive experience in this field.

C501 textbookThe course is presented in an alternating fashion, with hands-on practical sessions in the use of Microsoft Project, to facilitate project planning and control, being interspersed between successive project management foundational sessions. Course documentation includes a comprehensive course file, and the book 'Microsoft Project 2010 Step by Step' (or the older ‘Microsoft Project 2007 Step by Step’ until our stocks are depleted), by Carl S. Chatfield and Timothy D. Johnson, Microsoft Press.

Course Content

Module 1
Project Management - a primer

  1. Definitions
    1. Project Management
    2. Shutdown Management
  2. Scheduling principles
    1. Maintenance Scheduling Classes
    2. Network Scheduling (PERT/Critical Path Method Scheduling)
      1. Definitions
        Activity on arrow technique
  3. Getting started with Microsoft Project
  4. Scheduling Principles (continued)
    1. Activity on node technique
    2. Scheduling formats
  5. Creating a task list: hands-on exercise
  6. Scheduling Principles (continued)
    1. Resource planning
    2. Setting up a network plan

Module 2
Scheduling and project management principles

  1. Scheduling Principles (continued)
    1. Multiple time estimates
    2. Understanding the schedule
  2. Setting up resources: hands-on exercise
  3. Scheduling Principles (continued)
    1. Managing a project using the schedule
    2. A cautionary note
  4. Project Management Principles
    1. Sources of projects in maintenance
    2. Identifying valid project management instances
    3. The maintenance project manager – a profile
    4. The use of project management principles to advantage
  5. Assigning resources to tasks: hands-on exercise
  6. A business case for shutdowns
    1. Historical perspective on maintenance and shutdowns
    2. The objectives of maintenance
    3. Shutdowns as a means to implement the maintenance objectives
  7. Class assignment
  8. Formatting and printing your plan: hands-on excercise
  9. Preventive Maintenance principles
    1. Pro-activeness
    2. Maintenance Strategy options
  10. Class assignment
  11. Tracking progress on tasks: hands-on exercise

 Module 3
Shutdown and project planning principles I

  1. Preventive Maintenance principles (continued)
    1. Condition Based Maintenance principles
  2. Fine-tuning task details: hands-on exercise
  3. Individual assignment: hands-on exercise
  4. Preventive Maintenance principles (continued)
    1. Use Based Maintenance principles
    2. Variability in component lives
  5. Fine-tuning resource and assignment details: hands-on exercise
  6. Detailed project planning
    1. Determining the scope of the task
  7. Fine-tuning the project plan

 Module 4
Shutdown and project planning principles II

  1. Detailed project planning (continued)
    1. Manpower planning
    2. Procurement
      1. Procurement of Spares and Materials
  2. Organising and formatting project details: hands-on exercise
  3. Detailed project planning (continued)
    1. Procurement (continued)
      1. Procurement of external services, including renting of special equipment
      2. Procurement of manpower
    2. Safety and Quality requirements
      1. Internal quality
      2. External quality
  4. Class assignment
  5. Printing project information: hands-on exercise
  6. Project Management
    1. Management Planning
      1. Why is planning important?
      2. The planning process
      3. Planning and Control
  7. Tracking progress on tasks and assignments: hands-on exercise
  8. Project Management (continued)
    1. Project organisation
    2. Project leading
    3. Project control
  9. Class assignment
  10. Viewing and reporting project status: hands-on exercise

Module 5
Successful shutdown management

  1. The shutdown steering group
    1. Constitute the steering group
    2. The shutdown steering group agenda
  2. The shutdown manager
  3. The shutdown planning office
  4. Determining the shutdown scope
  5. Getting the project back on track: hands-on excercise
  6. Shutdown planning process
  7. Pre-shutdown work
  8. Post-shutdown re-planning
  9. Applying advanced formatting to the project plan: hands-on excercise


Note: Hands-on work is based on the Microsoft Press book 'Microsoft Project 2010 Step by Step' (or the 2007 book until stock is depleted) by Carl S. Chatfield and Timothy D. Johnson, of which each student receives a copy.


Who Should Attend

The C501 course is primarily intended for maintenance managers (to manage maintenance shutdowns and maintenance projects), and secondly for maintenance planners (who need to plan shutdowns and maintenance projects).

Important note: Laptop computer required – refer to terms and conditions on Course Registration form, and footnote on the Course Listing.

Credits 16*, level 5**

CPD Points: 5

* The course comprises 80 hours of study, of which 40 hours are in class, with a further 40 hours for the assignment.

**Occupational Certificate level

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