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26 Plant-Wide Formal Prioritization System Mike Palm, CMRP, PMP, CSSBB Convergent Results, LLC Why a Prioritization System? B efore we even get into a discussion of designing prioritization systems, we should answer the question of why do it in the first place: What is to gain? Why is the view worth the climb? Prioritization systems can be a bear to "enforce." Sometimes, they have grown to over a dozen confusing priorities, an unruly mixture of urgency, importance, and work type. In some cases, requesting organizations just do not comply. Everyone wants their job done ASAP, and some people are not the least bit concerned with the priorities and schedules of other departments. You can wind up with everything classified as Priority 1, which really means that there are no priorities at all. Maintenance is left to sort it all out. They are forced to pick and choose, with all the inherent risks to their working relationships, to establish their schedules. So if there is such a potential for difficulty, why should we establish a prioritization system for maintenance work? The answer can be wrapped up in a single word: dollars. The prioritization system establishes a plant-wide framework for identifying what work must be planned and what work can be unplanned. The objective is to achieve a system where 85-90 percent of the work being done is planned. In World Class Maintenance Management, author Terry Wireman discusses case studies showing that planning reduces job costs by as much as 90 percent. Unplanned work can cost four to ten times what that same work would cost if planned. In the Maintenance Planning and Scheduling Handbook, Richard (Doc) Palmer describes how, when work is planned, it can result in a 60 percent increase in crew productivity. Let's do the math using Doc Palmer's more conservative numbers: Going from a totally reactive (unplanned) environment to a 90 percent planned environment means a reduction in labor cost or an increase in capacity of 33 percent. This increased capacity can be focused on reliability improvement with its potential for increasing revenues and gross margins. SOLUTIONS AUGUST 2016 10127-4056 SMRP Solutions SE.indd 26 8/22/16 9:43 AM

Table of Contents for the Digital Edition of Maintenance Technology September 2016

Editorial
Uptime
On The Floor
Old-School Approach To New-World Technology
Art Meets Reliability Science
Commit To Safety
Robot-Human Interaction Getting Safer
Sanitary, Stainless Conveyors Not The Same
Reduce Hidden Process-Safety Costs
Pace Your Reliability Program
Win The War With 'Lubrication By Design'
SAP Tips And Tricks
Understand Pump Vibration
Select The Right Relay
Bearing Care
Clear Up HOA Confusion
Potato Waste Becomes Clean Water, Energy
Products
Showcase
Ad Index
Final Thought
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - Cover1
Maintenance Technology September 2016 - Cover2
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - 2
Maintenance Technology September 2016 - 3
Maintenance Technology September 2016 - Editorial
Maintenance Technology September 2016 - 5
Maintenance Technology September 2016 - Uptime
Maintenance Technology September 2016 - 7
Maintenance Technology September 2016 - On The Floor
Maintenance Technology September 2016 - 9
Maintenance Technology September 2016 - Old-School Approach To New-World Technology
Maintenance Technology September 2016 - 11
Maintenance Technology September 2016 - 12
Maintenance Technology September 2016 - 13
Maintenance Technology September 2016 - 14
Maintenance Technology September 2016 - 15
Maintenance Technology September 2016 - Art Meets Reliability Science
Maintenance Technology September 2016 - 17
Maintenance Technology September 2016 - 18
Maintenance Technology September 2016 - 19
Maintenance Technology September 2016 - Commit To Safety
Maintenance Technology September 2016 - 21
Maintenance Technology September 2016 - 22
Maintenance Technology September 2016 - 23
Maintenance Technology September 2016 - Robot-Human Interaction Getting Safer
Maintenance Technology September 2016 - 25
Maintenance Technology September 2016 - Sanitary, Stainless Conveyors Not The Same
Maintenance Technology September 2016 - 27
Maintenance Technology September 2016 - 28
Maintenance Technology September 2016 - Reduce Hidden Process-Safety Costs
Maintenance Technology September 2016 - 30
Maintenance Technology September 2016 - Pace Your Reliability Program
Maintenance Technology September 2016 - 32
Maintenance Technology September 2016 - 33
Maintenance Technology September 2016 - 34
Maintenance Technology September 2016 - 35
Maintenance Technology September 2016 - Win The War With 'Lubrication By Design'
Maintenance Technology September 2016 - 37
Maintenance Technology September 2016 - 38
Maintenance Technology September 2016 - SAP Tips And Tricks
Maintenance Technology September 2016 - Understand Pump Vibration
Maintenance Technology September 2016 - Select The Right Relay
Maintenance Technology September 2016 - Bearing Care
Maintenance Technology September 2016 - 43
Maintenance Technology September 2016 - Clear Up HOA Confusion
Maintenance Technology September 2016 - Potato Waste Becomes Clean Water, Energy
Maintenance Technology September 2016 - 46
Maintenance Technology September 2016 - 47
Maintenance Technology September 2016 - 48
Maintenance Technology September 2016 - 49
Maintenance Technology September 2016 - 50
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Maintenance Technology September 2016 - Showcase
Maintenance Technology September 2016 - Ad Index
Maintenance Technology September 2016 - 55
Maintenance Technology September 2016 - Final Thought
Maintenance Technology September 2016 - Cover3
Maintenance Technology September 2016 - Cover4
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