Unless there are extenuating circumstances, it would appear that the maintenance organization is staffed higher than needed to effectively operate the facility. Teamwork: Many tasks require more than one maintenance worker, meaning that those in the maintenance industry must work effectively and efficiently with others. Where is the plant located? Contract out your maintenance, the tax should be recoverable under business activity. Some business decision-makers also perceive maintenance technicians as “fixers” rather than “preventers” of equipment problems. Two shifts and one guy are a recipe for an early grave, or at the very least, a loss of morale and eventual burnout. Bodies and arms and legs DO count. Plant staffing levels can be determined by a number of different methods. How Many HR People Do You Need In 2020? In practice, this means that you’re responsible for deciding how many staff you need and recruiting enough staff to meet this. What insurance do I need for a small business? how many nights a week the child spends with you. how many children you’ll pay maintenance for. I have called the maintenance staff 20 times (yes, 20 times) over the phone to come and clean up this egg someone threw at my apartment. There is also a large CNC router that runs 16 hours a day, five days a week. only break glass call points) meets legal minimum standard it would be good practice to supplement this with some automatic detection in higher risk areas (e.g. Furthermore, we cannot ignore the specialized skills and knowledge requirements for condition monitoring and predictive maintenance. “What is the formula for determining the optimum maintenance staffing level for our plant?” someone recently asked. Still, I feel obligated to share my own thoughts as to the difficulties associated with maintenance staffing levels as we wrestle with maintenance costs, reliability improvement and an era of skills shortages. If you want to check it’s been worked out correctly, you can talk to an adviser. Understood. Reactive or repair-based maintenance is highly unpredictable in terms of scope, skills and duration due to high levels of unplanned, unscheduled, reactive work loads. On the other hand, determining the number of maintenance mechanics or technicians is not so simple—in fact, in some plants it is extremely complex. What Should I Do Next? The maintenance loan calculation for students starting in 2020 is based on their parents’ 2018-19 tax year income, and that is what should be put down in the first instance. © 2020 Efficient Plant. You'll need to figure that one out based on local employment pools and your existing employees. The forums are retiring in 2021 and are now closed for new topics and comments. When the two mechanics met and discussed the findings, they discovered that the new push rods were in the WRONG package from the manufacturer! one man jobs can be a real bear and are quite often impossible with one person, two man jobs are often far bit easier, three guys can handle most situations without breaking their backs (figuratively and literally)..Depending on the number of employees at the plant, you might also need one or two dedicated to the housekeeping duties We had two full time housekeepers, but then we had roughly 300 employees. Until these “skill sets” become core competencies for maintenance staffing, I believe it is IMPOSSIBLE to use a formula to determine the optimum maintenance staffing levels. If you want an expert team to help you, or if you just want to find out more information, then call Guardian. We see that our maintenance staffing is in the fourth quartile (the green area to the right). L. Get a regular maintenance schedule set up - Stopping problems is far superior to fixing them.Any reliable chief maintenance engineer should be able to organise their own dept if you let them so employ a good one and rely on them. no guys required. 9 years ago. Have you considered doing a side-by-side management costing? The training of other staff should also be considered, with depot managers and those responsible for supervising workers given more comprehensive, and perhaps formal, training. If you're running three shifts, then you need to ensure that there is sufficient staff on hand to cope with situations as they arise, so there will be a multiplier in effect, even if you have an oncall programAt a guess, you'll need at least two, if not three building maintenance staff depending on the workload (A tough call from a remote location and a general description). We all have our limits.good luck! For back-of-house staff, such as cooks, dishwashers, etc., one FTE equals 40 hours. Then (imo) it's of tantamount importance that you find at least one more well-rounded person to assist you. The Maintenance Staffing Calculator and User Guide are available on the TRB website by searching on TCRP Report 184. You can get a professional website for $1-2,000 instead of $10k+. The mistake many practices make is adopting an oversimplified and reactionary approach: If the work falls behind or one is pleading for help, they add staff. Cleaning staff should clean and disinfect offices, bathrooms, common areas, and shared electronic equipment used by the ill person, focusing especially on frequently touched surfaces. Because alot of the fusion equipment is made in Germany, there are no contractors in the state for service. While the root cause of the problem was obvious, neither mechanic had ever experienced mislabeled parts from this specific high-performance parts manufacturer. In call centers this is also a question often asked. I noticed that he was impressively meticulous about his work. I have asked the very same question about optimum maintenance staffing levels for over 20 years. This is for a single shift operation. Who should do it? Other departments and/or personnel that must be involved in improving “maintenance” include maintenance and repair parts procurement, inventory control, operations management and staff, process technicians, engineering, production scheduling, etc. Real-world exampleI spent time recently with a business that modifies and tunes high-performing street motorcycles using a custom-designed chassis dynamometer. – Lynn E. Krafft, ICAN/ATEX editor To read this response in its entirety, click here. There will always be design firms that have a talented, college-educated staff and charge a premium fee. In the interview, ask about living arrangements and discuss together how that will positively or negatively affect the applicant’s ability to do the job. Staffing levels are arbitrary, repetitive problems are not identified, common causes are overlooked, improper actions and rework go unnoticed. In general, maintenance includes very broad core job skills and knowledge such as in-depth principles of mechanical, machine repair, electrical, instrumentation/controls, machining, etc. In the case of the mental capacity, inspectors will need evidence that staff have been trained, but more importantly that they understand how the Mental Capacity Act 2005 and deprivation of liberty safeguards impacts general practice. It’s a tough one to answer. This design eliminates high amounts of friction and improves engine torque and horsepower measured at the rear wheel. The highly experienced mechanic who installed the new gear cams and push rods did not notice anything unusual during the assembly and adjustment. For a 5000 sq.ft usually a crew of 1-2 cleaning personnel might be enough especially if you have them work on a split shift. As for maintenance having someone on call should be adequate for your facility. Anyway, thanks for all the answers. Variable #2 – individual competencyThe second big variable for maintenance headcount is the skill set of each person—individual competency. A second highly experienced mechanic disassembled and inspected the new cams and push rods and immediately spotted a problem: The wrong push rods were installed! Gee, aircraft mechanics and top NASCAR race team mechanics do that all the time. (3 – 5 minute read) Most small and mid-sized businesses create more formal HR processes and departmental structures as they grow. But, adjusted to their maximum limit, they flexed while running under load, limiting the valve travel and causing a reduction in torque and horsepower. I’m sure there may be some readers out there who have mastered this mythical formula, or have come up with an effective method for their respective situations. Maintenance is rarely a narrowly focused job role, either geographically in the plant or intellectually in the skills and knowledge requirements. I have known businesses that hire the equipment that require maintenance in line with the OP - the argument being that it is cheaper and often quicker. Funny how you don't realize how many mistakes are in a post until after you hit send. Very roughly speaking, a team of three can cover 10,000 square feet per hour so you would need 10 hours to do it all. Current information about maintenance workforce demographics, hiring trends, retirement forecasting and knowledge retention often is overlooked, not fully understood and/or not factored into the staffing level decisions. Keep a tab on the home appliances and take up varied preventive measures which will help you save on maintenance costs. However, when undertaking combined inspection and testing, a greater level of knowledge and experience is needed, and the person will need: the right equipment to do the tests Can you out-source it to local companies ? Variable #4 – historical informationWork orders capture a whole host of information about maintenance and repair work, including problems, causes, corrective action and laborhours worked by named technicians. For some maintenance work, eg the changing of abrasive wheels, there are well-established industry training schemes. For example, determining the number of operators for machinery, material handling or control stations is a relatively simple task due to the number of operating positions, job tasks, narrowly focused scope of work and specific but limited skills and knowledge requirements. I need to prove a point to the brass that one or even two can't do it. For example: do they need to be on-site all the time and will they have authority to make changes to the business where its necessary to reduce risk of harm? Check out the happy tag. I am a friend of the owner, but he has delegated management to two individuals who have no clue what it takes and aren't open to suggestions. At an industial facicilty that cuts and welds polypropylene sheet to make huge tanks for steel mills and other industries, three buildings, 24000 sq. We also must include equipment-specific, facilityspecific task skills and knowledge. In 1948 the NHS employed 144,000 staff. Step 1 - working out income. One, me, and no. You’ll need to say: how much you earn. More and more plants will experience higher maintenance costs and higher turnover of top skilled people as the “maintenance skills shortages” grips our nation’s business and industries, furthering the inability to determine proper maintenance staffing levels. In other cases, such as for the use of small-scale scaffold towers, sufficient training may be provided by the hirers of such equipment. For example, it would be very dangerous to have a water based fire extinguisher for use in a server room as we all know that water and electrics do not mix very well. FTE stands for “full-time equivalent,” meaning how many people it takes to equal one full-time person. Identifying Issues : When there is some technical issue, maintenance workers must be able to … This development is a response to the need to acquire talent, increasingly complex compliance demands and culture challenges that arise with new staff. Many landlords make arrangements for a maintenance person to live on site or provide them with housing nearby. As many as you can afford. ft for mixed sizes of offices, 5 propane forklifts, 1 mobile crane, 4 overhead cranes, 2 utility trucks, 2 heavy duty pickup trucks, several powertools, several extrusion machines, various rigging lifting and handling apparatus, a 25HP rotary screw compressor and a 10HP dual piston compressor, various shop machines and saws, seveveral pneumatic presses and fusion machines, and tons of other miscellaneous stuff. Guidance for operators about the safe operation and maintenance of lorries, buses, coaches and trailers. 0 0. Do I need to have heat / smoke detection linked to the fire alarm? But, in many cases, maintenance can be done in-house by suitably trained, competent staff. It is almost impossible to plan anything day-to-day, let alone the proper staffing levels. The maintenance people took over an hour to come and clean it up. Ah. How they are allocated among the trades would depend in part on the quality of the construction. I just want to make things work. Regrettably, for decades “maintenance” has been treated as an overhead expense line item and a “non-value-adding” activity in many business operations. How many guys do I need to maintain it all? Unfortunately, there seems to be no logical or easy answer to this seemingly straightforward question. How do I report maintenance staff? In many low-risk environments, a sensible (competent) member of staff can undertake visual inspections if they have enough knowledge and training. How reliable is it ? The consultant workforce grew by 54% between 2002 and 2012 and annual growth of 4% is predicted until 2020. There seems to be an “assumed” higher level of maintenance competency than what actually exists, or an over-simplification of the job roles that gets some plants into deep trouble. Then reduce that figure by up to 500 calories a day to start losing weight safely. If you're running three shifts, then you need to ensure that there is sufficient staff on hand to cope with situations as they arise, so there will be a multiplier in effect, even if you have an oncall program At a guess, you'll need at least two, if not three building maintenance staff depending on the workload (A tough call from a remote location and a general description). These firms provide a top-notch product but don’t satisfy every small business’s budget. If you have a very RELIABLE plant and equipment, the maintenance workloads are usually very well defined in terms of scope, skills and duration due to planned, scheduled and preventive/predictive maintenance. The facility size is 1.2 million SF. It sorta depends on how old and/or prone to failure the machinery is, and how mission critical each unit is to facilitate continuous production.Also, take into account the shift situation. While this varies by business type, size and market area, as a company reaches maturity, a reasonable average is … Whilst a manual system (e.g. Here are the BIG variables that affect maintenance staffing level decisions: Variable #1 – scope of work The breadth and depth of job-performance requirements varies widely in today’s industries from extremely-narrow, single-task, repetitive job tasks to broad, multi-skill job roles. Such subtle differences in today’s mechanics’ skill sets—or competencies—can create or eliminate maintenance-induced failures and the need to rework a recently completed job. If all maintenance people had the same level of skills and knowledge, there could be an easy answer to the question of “optimum maintenance staffing levels.” BUT, there is a lack of comprehensive skills standards as applied to industrial maintenance job roles especially in the areas of equipment-specific tasks. In many plants I’ve often heard this scope of work scenario described as “an inch wide and a mile deep for equipment operators” and “a mile wide and a mile deep for maintenance technicians.”. To figure that out, you first have to understand what an FTE is. Can't be sure, but I know of one plant located somewhere close to there that does this kind of work...Anyway, at my last 'brick and mortar' job, located in a suburb of Cleveland, we had three locations that each specialized in a different area of the company's products. All clinical staff. Two teams of three working for 5 hours will get the job done in half the time. Flash forward to our day, websites need maintenance. It is in a rural area, 32 miles from metropolitan Pittsburgh. Some of this stuff is safety critcal and your local authorities would look better on you if your fork-lifts and cranes were maintained and/or checked by specialists. Today, many plants do not FORMALLY train and qualify all of the maintenance staff to address the maintenance and reliability needs of the plant’s equipment and facilities. If I'm not mistaken , the company's holdings were about three times your facilitiesWe had a staff of ?seven (or possibly 8) full time general maintenance employees, responsible for building maintenance (dealing with plumbing issues, electrical systems, lighting, equipment moving, furniture, stowage of building related chemicals, hardware, etc, and housekeeping). So how many employees is enough? The Maintenance Staff- ing Calculator is very flexible and can be used by all types of agencies for very detailed analyses or quick snapshots. Why do you need maintenance men? Answer You need a very mixed skill-set to deal with it all - motor mechanics, machine tool specialist, electrician.How old's the kit ? The amount of staff you need depends on a number of things relating to your service and the people you support. 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