PILLAR 5 - WORK MANAGEMENT

Sample Questions

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1. Which performance result best reflects to a maintenance and reliability manager

that the scheduled maintenance activities being implemented are effective:

Hours spent on unscheduled maintenance have decreased

Overtime has been reduced

Maintenance cost per unit have decreased

Total annual maintenance costs have decreased

2. The following formula [(Work Order Cost / Planned Cost) x 100] is a calculation
for what?

Planned hours vs Actual hours

Planned costs vs Actual cost

Planned labor vs Actual labor

Planned material cost vs Actual material cost

3. MRO stands for:

Materials, Repairs, & Overhauls

Manning, Repairs, & Overtime

 Materials, Replacements, & Operations

Maintenance, Repairs, & Operations

4. Work Prioritization should take into account which of the following?

Critical Equipment, Severity, Environment, Management

Operating Environment, Consequence, Cost, People

People, Financial Risk, E&H, Reputation, Likelihood of occurrence

Operation Disruption, People, Environment, Material Availability

5. 5S is:

Sort, Standardize, Set in Order, Sustain, Safety

Sort, Set in Order, Shine, Standardize, Sustain

Sort, Shine, Standardize, Sustain, Safety

Set in Order, Shine, Standardize, Sustain, Safety

6. Inventory turns are calculated by:

(Total value of receipts / inventory value) x 100

(Total value of receipts / total value of parts issued) x 100

(Total value of issues / total value of inventory) x 100

(Total inventory value / total value of receipts) x 100

 7. When developing shutdown, turnaround, or outage plans the following should
not be considered:

Shutdown & Outage Strategy

Procedures and policies

Managers “Wish-List”

Authorities

8. The three (3) main drivers in calculating OEE are:

Quality / Speed / Downtime

Quality / Rate / Availability

Quality / Availability / Yield

Availability / Rate / Downtime

9. The activity code in the CMMS is to specify which of the following?

What type of work was performed

Whether it was planned or unplanned

The number of tasks performed

Whether it was direct or indirect work activity

10. Risk Based Inspections (RBI) involves all of the following except?

Prioritization

Objectives
 Standards

Qualified Resources

11. When determining travel time, the average person walks?

Less than 1 mph (1.6 kph)

2 mph (3.2-4.8 kph)

3-3.5 mph (4.8 – 5.6 kph)

5 mph (8 kph)

12. Which of the following is not part of the Work Management process?

Identification

Approval

Procurement

Prioritization

Close out & Review

13. When Job Planning, all of the following are important steps except?

Scope and procedures

Materials and tools

Developing job package

Testing and inspection processes

 Job Assignments

14. MRO Storerooms should strive for what inventory turn ratio?

<1

4-6

>10

15. Staging & Kitting of materials is best applied except for:

Emergency Work

Planned Corrective Work

PM’s

Outages and Shutdowns

16. Which of the following is the most challenging of a major shutdown and
turnaround?

Time

Contractors

Determining Critical Path

Scope Management

17. Scheduling includes which of the following?

 1. Balance resources

2. Manage backlog

3. Produce work schedule

4. Manage break-in

5. Coordinate equipment access with Ops

1–3–5

1–2–3–5

2–3–5

1–2–3–4–5

18. When planning for a major shutdown or outage, what must be identified to
ensure success:

Having the right contractors

Determining Critical Path

Having the materials & tools available

Establish “float”

19. Min/Max levels are determined by:

Monthly usage

Economic Order Quantity (EOQ)

Whatever the Maintenance Manager wants it to be

Based on gut feel

 Average consumption during lead-times

20. Current best demonstrated OEE is 55% with revenues of $220M. What would
revenues be if OEE increased to 70%?

$305M

$280M

$60M

$253M

21. Work Management includes which of the following except?

Planning & Scheduling

Quality assurance

Materials and tools

Root Cause Analysis (RCA)

Close-out and analysis

22. What is considered world class inventory accuracy?

Greater than 85%

Greater than 90%

Equal to or Greater than 95%

Equal to or greater than 98%

23. Inventory turns is a good metric to measure the following except?

Obsolescence

Too much inventory

Determine Critical Spares

Determining the right mix of inventory

24. What is the Economic Order Quantity (EOQ) if annual demand is 1200 units,
Carrying cost is calculated at 21.5%, order processing is $90, and unit cost is
$495?

25

32

45

71

25. The average length of operating time between one maintenance action and
another is the definition for what KPI?

Mean-Time-Between-Failure (MTBF)

Mean-Time Between-Maintenance (MTBM)

Mean-Time-To Repair (MTTR)

Mean-Time-Between-Shifts (MTBS)

26. Considering the four tools listed, which identifies those that are most
appropriately used as leading techniques to improve maintenance and
reliability?
 Total Productive Maintenance (TPM), Reliability Centered Maintenance (RCM),
Historical analysis and spending, Process benchmarking

Total Productive Maintenance (TPM), Reliability Centered Maintenance (RCM), Failure

Modes Effects, & Analysis (FMEA), Process benchmarking

Total Productive Maintenance (TPM), Reliability Centered Maintenance (RCM),

Historical analysis and spending, 5Y

Total Productive Maintenance (TPM), Root Cause Failure Analysis (RCFA), Developing
"Bad Actor" pareto, Process benchmarking

27. A medium to high-speed machine misalignment condition is best indicated by?

Displacement analysis at a frequency of greater than 2 kHz

Ultrasound measurement in the range of 40-50 kHz

Velocity measurement in the frequency range of 0-2 kHz

Shock pulse measurement in the range of 30-40 kHz

28. Quality of the work is the responsibility of?

Plant Manager

Operations Manager

Work Management Team

Maintenance Manager

29. The purpose of developing a formal prioritization system is to?

Take the emotion out of work priority

Schedule by Operations priority

 Schedule the work that can be completed the quickest

Satisfy customer orders

30. Work Close-out and Analysis is important for?

Identifying who didn't complete their work

Define scope creep

Compare actual work to planned

Scheduling the next job

31. Fill in the blank: _____________ failures cannot necessarily be addressed through
fixed time, predictive or condition-based maintenance programs. Instead, these
failures must be prevented through proper design & installation, repeatable
work procedures, proper specifications, and quality assurance of parts.

Age-related

Random

Infant mortality

None of the above

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