How to calculate manpower for Preventive Maintenance

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Following steps can be followed for calculating manpower for preventive maintenance(pm) team.

Step 1 : Clearly define what all are the activities to be done on a machine as a part of preventive maintenance. For example, where to lubricate, where to clean, how much oil to be filled, what to inspect etc.

Step 2 : Now conduct time study on each activities for calculating how much time is required to complete an activity.

You can refer article on ‘Direct stopwatch time study’ for knowing how to do time study.

The output of this step will be total standard time required for completing an activity.

Apply the concept of manhour if more than one manpower is required for completing an activity.

Adding all the time required for all activities, gives total time for PM on a machine.

Total time should be in man hour or man minutes. If the manning of the activity is one it can be minute or hour.

Step 3 : Now decide the frequency of PM on a machine. For example, once in a week or once in a month.

Step 4 : Now take the count of no of machines.

Step 5 : Calculate total man minutes required for PM for a month for all machines

= Total man minutes for PM for a machine x No of machines x Frequency of PM per month for a machine.

Step 6 : Divide total man minutes required for PM for all machines for a month by working time of an employee per month.

Step 7 : Round up the value you got in step 6. This gives the manpower required per day for PM.

If this value is below one and if any of the activity requires two manpower to do a job, you may need to allocate two manpower, otherwise one person will not able to do that activity.

How to calculate manpower for Preventive Maintenance : Example

Total man minutes for one PM of a machine = 55 man minutes

Total no of machines = 150

Frequency of PM for a machine = twice a month

Total man minutes required for PM for a month for all machines = 55 x 150 x 2

= 16500 man minutes

Working time of an employee per shift = 420 minutes

No of working days in a month = 25

Working time of an employee per month = 420 x 25

= 10500

Manpower required per day for PM = 16500/10500

= 1.571

Say = 2 people

We have finished our calculations.

Please note that for for utilizing the calculated manpower properly, we may need to schedule the PM of machines properly.

In some cases we may need schedule activities in one PM for different days.

Hope this article is helpful to you. If there is any suggestion, please leave a comment in the suggestion page.

You may also interested to learn about clit sheet and autonomous maintenance.

Thank you.

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