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Optimal Maintenance Staff Plan: Determining Technician Numbers Based on Machines in Operation

Question:

When creating a maintenance staff plan, it is essential to determine the optimal number of technicians needed based on the number of machines in operation. This includes considering the necessary amount of electricians, mechanics, PdM techs, Reliability Engineers, and other personnel required to support the equipment efficiently. Are there industry benchmarks or studies available that correlate the number of pieces of equipment to the appropriate level of maintenance personnel needed for optimal performance?

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A few years ago, I undertook a thorough process that proved to be quite time-consuming but essential for proper maintenance planning. This process entails meticulously identifying all equipment, systems, and spaces in need of maintenance. By identifying maintenance tasks such as PM, PdM, repairs, mods, and customer calls, along with their frequency and estimated labor hours, you can calculate the total labor hours required. Adjusting this number for technician wrench time efficiency is crucial. To determine the actual labor hours contributed by an employee, start with 52 weeks multiplied by 40 hours, deducting non-working time like vacation, sick days, training, and company meetings. This will give you the labor hours per employee per year. By dividing the maintenance hours required by the labor hours per employee per year, you can estimate the number of technicians needed for the job. Setting up a CMMS or work order system plays a significant role in this process, as it involves tasks like equipment identification, task identification, and labor hour estimation. If you're short on time, consider visiting www.ifma.org to order their benchmarking research report, which provides valuable insights into facilities maintenance costs and staffing requirements based on square footage. Another helpful resource could be RS Means Facilities Maintenance and Repair Cost Data, although the most recent version may need to be sought out. Good luck on your maintenance planning journey!

Determining the appropriate number of personnel is not a one-size-fits-all process. It involves industrial engineering techniques such as time studies. Understanding wrench-time concepts and ensuring planners are familiar with personnel qualifications and task completion times based on experience levels are essential. Conducting a thorough RCM analysis and identifying critical equipment within your facility can provide valuable insights to establish the optimal number of personnel needed to effectively run your program. This approach, when executed correctly, can be a great starting point in workforce planning.

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Frequently Asked Questions (FAQ)

FAQ: 1. What factors should be considered when determining the optimal number of maintenance technicians based on the number of machines in operation?

Answer: - Factors to consider include the types of machines, their criticality, maintenance requirements, complexity, and the skill sets needed for maintenance tasks.

FAQ: 2. Are there any industry benchmarks or studies available to guide in determining the appropriate level of maintenance personnel for optimal performance?

Answer: - Yes, there are industry benchmarks and studies available that correlate the number of pieces of equipment to the appropriate level of maintenance personnel needed. These benchmarks can provide valuable insights into staffing ratios and best practices.

FAQ: 3. How can one ensure that the maintenance staff plan effectively supports the equipment and operations?

Answer: - To ensure the maintenance staff plan is effective, regular reviews and adjustments based on workload, downtime analysis, feedback from technicians, and performance metrics are essential. Continuous improvement processes should be in place to optimize resource allocation.

FAQ: 4. What are the typical roles that should be included in a comprehensive maintenance staff plan?

Answer: - A comprehensive maintenance staff plan should include roles such as electricians, mechanics, Predictive Maintenance (PdM) technicians, Reliability Engineers, and other personnel with specialized skills required for maintaining different types of equipment efficiently.

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