COURSE OVERVIEW:

The core meaning of this course is the strategic synchronization of manufacturing output requirements with the technical necessity of asset care. In many industrial environments, a natural friction exists between the production team’s drive for volume and the maintenance team’s requirement for equipment access. This course focuses on breaking down these silos by implementing an integrated planning framework that treats maintenance as a prerequisite for production rather than a competitor for time.

The scope of this training involves the technical alignment of the Master Production Schedule (MPS) with the Preventive Maintenance (PM) forecast. Participants will examine the methodologies for "Capacity Leveling," ensuring that both labor availability and machine uptime are realistically accounted for in the planning cycle. The curriculum emphasizes the "Activity Control" phase, where real-time adjustments are made to the schedule based on equipment breakdowns or raw material delays, requiring a dynamic and collaborative response from both departments.

Coverage includes the use of "Sales and Operations Planning" (S and OP) to forecast long-term maintenance windows and the implementation of "Integrated Scheduling Meetings" to finalize weekly commitments. Attendees will explore the impact of "Changeover Optimization" and how maintenance precision can reduce the time required to switch between production runs. By the end of this course, participants will be able to design a unified scheduling system that maximizes plant throughput while guaranteeing the long-term reliability of the production assets.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the technical interface between Production Planning and Maintenance Scheduling.
• Align the Master Production Schedule (MPS) with the annual maintenance plan.
• Implement "Capacity Requirements Planning" (CRP) that includes maintenance downtime.
• Conduct "Integrated Scheduling Meetings" to resolve conflicts between Ops and Maintenance.
• Utilize "Finite Capacity Scheduling" to create realistic daily activity plans.
• Minimize "Changeover and Setup" times through maintenance-supported SMED.
• Manage "Break-in Work" without destabilizing the production plan.
• Calculate the "Lost Opportunity Cost" of deferred maintenance.
• Develop "Standard Operating Procedures" (SOPs) for equipment handover and takeover.
• Monitor "Schedule Compliance" for both production output and maintenance tasks.
• Use "OEE" (Overall Equipment Effectiveness) as a shared performance metric.
• Foster a "Partnership Culture" through shared goals and transparent data.

TARGET AUDIENCE:

This course is essential for Production Planners, Maintenance Schedulers, Operations Managers, Supply Chain Coordinators, and Plant Supervisors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.