This is an analysis of a questionnaire that was undertaken by Alshahed for a construction company.

Result analyse:

Introduction
This is an analysis of a questionnaire that was undertaken by Alshahed for a construction company. The questionnaire was majorly written and were given to the engineers of the construction company and only 5 of the responded to the questions. The company consists of 93 employees. 85 manual workers and 8 engineers.

These six survey done by Alshahed for projects ( Contractor for construction) company .
The company have 85 workers and 8 engineers, 5 of the engineers answers these 6 survey
We print the survey and they solve it by hand we use excel to draw the diagram because its easy….

A=Maintenance engineer
B=Construction manager
C=Project manager
D= 5 site engineer
F=Electrical engineer

Calculate sample size

Rating System

5 The statement is true in all instances
4 The statement is true in most instances
3 The statement is somewhat true
2 The statement is somewhat false
1 The statement is false in most instances
0 The statement is false in all instances

Leadership

Score

A B C D F
1 Everyone values better maintenance as a way to improve business results It is a part of the plant’s mission and strategy 3 2 2 3 3
2 There are written goals, objectives and targets for maintenance improvement that improve business results 3 4 3 3 5
3 There is a multi-level plant leadership committee that works on continuously improving the maintaining function 4 5 4 4 5
4 Everyone understands that maintenance is a responsibility of everyone in the plant, not just the maintenance personnel 4 5 4 5 5
5 The plant has an ultimate goal of zero downtime due to equipment breakdowns 3 5 4 5 5
6 Maintenance System performance is routinely measured and reported against goals 5 3 4 5 4
7 Maintenance corrective action is permanent fixes vs. constantly fixing recurring problems 5 3 5 5 2
8 Housekeeping and equipment cleanliness have high emphasis, and are everyone’s responsibil- ity 5 4 5 4 5
9 The plant insists that scheduled preventive maintenance tasks are done as a part of operational planning 5 5 5 4 5
10 Everyone understands that equipment must be well maintained to be safe 4 5 5 5 5
11 Everyone understands that equipment must be well maintained to produce a quality product 5 5 4 3 5
12 Everyone understands that equipment must be well maintained to get best productivity 5 5 4 4 5
13 Everyone understands that equipment must be well maintained to get the lowest product cost 5 5 5 5 5
14 Ongoing work in maintaining and improving equipment reliability is valued more than good firefighting type maintenance 4 4 4 5 2
TOTAL

Diagram:

Comment: According to A, Everyone needs to play a leader’s role in ensuring that all equipment are well maintained in order to ensure that they at all times produce optimum quality products. The engineers B, C, D, and F also have proven the same as they all gave an average rating of 4.

Preventive Maintenance
Score

A B C D F
1 There is a formal periodic equipment cleaning/inspection system (PM) in place that identifies potential problems before they become downtime issues 3 5 4 4 5
2 Equipment listings and PM Procedures are current and accurate 3 4 5 4 5
3 Inspections are always carried out exactly as specified, when specified 4 5 5 5 4
4 Preventive maintenance work has the highest priority in the maintenance planning and sched- uling effort. Only serious safety, quality and imminent breakdown issues have a higher prior- ity than PM work 4 2 5 5 3
5 There are procedures in place to make sure that preventive maintenance procedures, which do not happen as scheduled, are not forgotten and still get done 3 5 5 5 5
6 Potential problems are identified and work orders are entered to correct them 5 5 5 5 5
7 The majority of repair work orders are generated from preventive maintenance inspections 5 5 5 5 5
8 The essential principle of “Clean to Inspect” is well understood by those performing PM work 5 5 5 5 5
9 When a breakdown occurs, preventive maintenance procedures are reviewed and adjusted as necessary to prevent the problem from reoccurring 5 5 4 5 5
10 Preventive Maintenance procedures are reviewed and updated when there are changes in equipment or practices 4 4 4 5 4
11 There is a lubrication program that makes sure equipment is lubricated routinely and properly with the proper lubricant 5 4 5 5 2
12 Lubricants and lubrication equipment are stored and maintained properly, to avoid contamina- tion problems 5 4 5 5 3
13 There are measurements in place to monitor the performance and the results of the Preventive
Maintenance Process 5 3 5 4 4
14 Operating personnel have most of the responsibility for preventive maintenance work that is done while equipment is running 5 4 4 4 4
15 There is an ongoing review process involving operators and maintenance personnel to move as much PM from a downtime to a runtime activity 4 5 5 5 5
TOTAL

Diagram:

Comment: It is always a good practice to prevent disease rather than cure. This also applies to plant maintenance. As per engineers C and D, the plant will be maintained and put into its correct model specifications occasionally not waiting for future scheduled maintenance to happen.

Planned Maintenance
Score

A B C D F
1 The plant strongly supports the concept of planned and scheduled maintenance as the most ef- ficient, effective way of performing maintenance and all departments are committed to its suc- cess 4 4 3 5 5
2 A work order system is in place to allow effective management of maintenance work 4 5 4 5 4
3 There are individuals in roles dedicated to the planning, scheduling, and coordinating of main- tenance work 4 5 4 5 5
4 The value of planning work orders is well understood and accepted 5 4 5 4 4
5 More than 80% of non-emergency Work Orders are planned 5 5 5 4 4
6 The value of maintenance scheduling is well understood and accepted 4 5 5 4 4
7 A weekly maintenance schedule is always prepared and agreed on by operations and mainte- nance in a weekly meeting 3 2 5 4 3
8 The maintenance schedule is reviewed and updated daily and W/Os are assigned to individu- als 4 2 4 4 3
9 There is a priority system used for ranking and scheduling maintenance work that is under- stood and accepted across the plant 3 4 4 5 4
10 More than 80% of the work scheduled to be done in a week gets done in that week 5 4 4 5 4
11 The various reasons for scheduled work not getting done are reviewed and discussed in the weekly maintenance-scheduling meeting 5 5 4 5 4
12 Emergency work is less than 15% of the normal weekly maintenance hours 5 5 4 3 3
13 Routinely the right materials and resources are brought together at the right place and at the right time to work on properly prepared equipment 5 5 5 3 5
14 The necessity of an adequate maintenance backlog is well understood 5 5 5 4 4
15 The backlog of available scheduled work orders is maintained at the three to four week level 5 5 5 5 4
16 Kits of parts planned for work orders are routinely prepared in advance for scheduled work orders 4 4 5 5 5
17 It is understood and valued that accurately completed work orders greatly help the planning and scheduling of maintenance work 4 4 5 5 5
18 It is understood and valued that the accurate recording of labor and parts allows accurate cost projections for budget and spending justification 5 5 4 5 5
19 Previous work orders are routinely referred to and used for planning information on work or- ders 4 4 5 5 4
20 Standard procedures and parts lists have been built and are used for planning repetitive main- tenance work 5 4 5 3 5
21 Adequate documentation, parts lists, manuals, drawings, etc are readily available, and used in maintenance planning 4 5 5 5 5
TOTAL

Diagram:

Comment: Planning is important for the success of any undertaking. In accordance to the response by A and D, the plant must have a time schedule for planned maintenance on all necessary and emerging issues. The scheduled maintenance timetable is updated regularly to ensure there is total security for the plant.

Reliability Improvement

Score

A B C D F
1 Work orders are always completed with all relevant actual information (parts procedures man- hours), to allow analysis for recurring problems 4 5 5 4 5
2 Analysis of repair work orders is a regular, routine task, performed with operating teams to avoid breakdowns and improve reliability 5 4 5 3 5
3 Trend information on maintenance downtime and maintenance costs is readily available for each piece of critical equipment and is referred to routinely to generate maintenance work 5 5 5 4 4
4 There is a formal system to attack equipment problems that involves thoroughly determining the underlying root cause 5 5 5 4 3
5 Maintenance personnel are available to assist operating teams with reliability improvement analysis and correction 4 3 4 5 3
6 Technical resources, such as engineers or experienced technicians, are available to assist teams with reliability improvement 3 2 4 5 2
7 Equipment downtime is tracked and reviewed periodically 2 5 5 5 5
8 A reliability team with members from production, engineering, and maintenance review top downtime issues regularly 5 4 5 5 5

TOTAL

Diagram:

Comment: According to engineers B, C, D, and F, all pieces of equipment are guaranteed perfect care and maintenance in the event of failure or downtime. The costs of repair is also affordable. However, engineer A somewhat does not agree with the other engineers.

Personnel Training

Score

A B C D F
1 There is a formal listing of the maintenance training and capability required by operators 5 5 3 5 5
2 There are routine mechanisms and materials to periodically provide Maintenance Training to
Operators and Mechanics 5 5 3 5 5
3 Maintenance skills taught to operators and maintenance personnel are used immediately in their jobs 5 5 4 5 5
4 Operators routinely assist maintenance personnel with repairs 5 5 4 5 4
5 Maintenance personnel or Senior Operators routinely assist newer operators in developing preventive maintenance skills 4 5 4 4 5
6 There is a formal listing of the maintenance training and capability required by maintenance personnel 4 5 5 4 4
7 There are committed routine systems to communicate maintenance information between in- dividuals 3 4 5 5 3
8 There are job descriptions for maintenance & maintenance management personnel that have been reviewed with the employees 4 3 5 3 4
9 Reviews of skills & skill requirements are held annually and reviewed with all employees 4 3 5 4 5
10 Employees are required to attend “refresher” skills training periodically 5 4 4 4 5
11 There are job descriptions for operations personnel that have been reviewed with the em- ployees 5 5 5 5 4
12 There are standard maintenance procedures that are reviewed and followed for maintenance jobs 5 5 4 5 3
13 There are standard operating procedures that are reviewed and followed for all processes 5 5 5 5 4
14 Operations personnel assist maintenance in developing operational skills 4 3 4 5 4
15 There is a formal listing of the operational training and capability required by maintenance personnel 5 4 5 4 3
16 Operational skills taught to maintenance personnel and operators are used immediately in their jobs 4 5 5 4 5
TOTAL

Diagram:

Comment: A, B, C, D, and F agree that the training of personnel is guaranteed. They also accept the fact that apart from personnel being trained, they also review their skills and are thought new skills regularly. This is evidence that good mechanisms that have been put in place to keep up the necessary skills in personnel that will ensure proper equipment operation.

Parts Administration

Score

A B C D F
1 Everyone understands that lowering the levels of emergency and unplanned maintenance work, allows corresponding lower levels of in- house, spare parts inventory 4 4 4 4 4
2 Guidelines for in-house maintenance spare parts stocking decisions and stocking levels are in place 5 4 4 4 4
3 The reasons behind the guidelines are well understood by all plant personnel 5 4 4 5 4
4 Maintaining as much inventory with suppliers as possible is a stated objective in the spare parts guidelines 4 4 5 5 5
5 An objective of spare parts inventory turns per year has been set 5 5 5 4 5
6 Stock outs of critical parts are at the <5% level 4 4 4 5 4 7 Spare parts usage is always captured promptly on work orders or requisitions to keep inven- tory information accurate 4 4 5 5 5 8 Vendor performance is evaluated annually using system information 4 5 5 4 4 9 Spare parts storage is well organized 5 5 5 3 5 10 Cycle counting of spare parts is performed regularly and frequencies of counting parts are based on their ABC classification 3 5 5 4 5 11 Cycle counts have a small (<5%) variance against system counts 4 5 3 4 5 12 Maintenance purchasing is a centralized efficient activity driven by inventory and scheduled work order requirements approximately three times per week 4 5 5 5 5 13 Annual contracts are in effect with major suppliers, to reduce the purchasing effort 5 4 5 5 4 14 Emergency Purchasing and Expediting is an infrequent activity 5 5 5 5 5 TOTAL Diagram: Comment: According to B, C, and F, records of the spare parts inventory are always kept for future predictions and annual assessments of parts administration. Spare parts are kept in secure locations and conditions after purchase. All the engineers also agreed that whenever a spare part needs to be used, it must be documented and recorded when it was used. Conclusion This assessment has evidently proven that the construction company has taken into consideration all the plant maintenance techniques that would be recommended by any award winning engineer. All the five engineers who responded to the questionnaire individually expressed a common satisfaction in the model that the company is implementing in maintaining all of its machinery.