How they transformed maintenance scheduling

Challenge

DTE Energy, with its expansive workforce and multiple facilities, faced significant difficulties in managing maintenance scheduling and resource allocation effectively. Their existing processes were inefficient, time-consuming, and lacked the necessary visibility and automation to keep up with operational demands. These challenges included: 

• Scheduling Compliance Issues: Manual, work order-by-work order scheduling was cumbersome, making it difficult to track and meet compliance requirements.
• Lack of Visibility: Employees had no clear way to see which tasks were scheduled, in progress, or completed, leading to inefficiencies and wasted time.
• Ineffective Resource Allocation: Uncertainty around workforce availability and limitations in personnel sharing caused delays and inefficiencies.
• Backlog Management: An overwhelming backlog filled with duplicate and outdated work orders made it nearly impossible to manage and prioritize tasks efficiently.
• Time-Consuming Scheduling: The lack of bulk editing and automation meant that scheduling required excessive manual effort, slowing down operations. 

Solutions

To address these persistent challenges, DTE Energy sought a robust scheduling solution that could simplify and standardize their work management processes. They chose Prometheus Scheduler for Maximo for its flexibility, ease of use, and ability to handle large data sets efficiently. Key elements of the solution included: 

• Standardized Workflows: A dedicated team developed Work Management Procedures and Process Maps to bring consistency across all facilities.
• Automated Scheduling & Compliance: vScheduler enabled one-click scheduling, assignment tracking, and compliance reporting. 
• Improved Workforce Management: vCalendar provided an intuitive way to manage shifts and track workforce availability in real-time.
• Payroll Integration & Accuracy: vTimeSheet automated time reporting and payroll processing, reducing administrative burden. 
• Backlog Cleanup & Job Plan Standardization: vJobPlan helped eliminate outdated work orders and establish standardized job plans. 
• Mass Data Updates: MPower allowed for bulk modifications in IBM Maximo, streamlining asset and work order management. 

Results

Following the implementation of Prometheus Scheduler for Maximo, DTE Energy experienced significant improvements in scheduling efficiency, backlog management, and overall operational productivity. The key benefits included: 

• Backlog Reduced by 20-25%: Clear visibility into work orders enabled quick identification and removal of outdated entries, improving organization.
• Efficiency Increased by 30-35%: Bulk editing capabilities and streamlined scheduling processes allowed the team to complete tasks faster.
• Over $2.7 Million in Time Reallocated: By reducing time spent on manual scheduling, thousands of hours were redirected toward higher-value work.