Project spotlight

Mark Redmond

The modelling of maintenance technician resource requirements for a biopharmaceutical facility

Student: Mark Redmond

Degree: Part time, Direct Taught MSc in Maintenance Engineering and Asset Management

Qualification: BEng, MSc

Country: Ireland

Sponsor: Pfizer, Ireland

Collaboration: Pfizer, Ireland  

Current position: Maintenance Engineer, Pfizer, Ireland

Awards: Top Part Time MSc in Maintenance Engineering and Asset Management 2006-2009

Supervisor: Dr Rodger Edwards

I came to University of Manchester to continue my studies in the Maintenance Engineering & Asset management. The University of Manchester is one of the world leading institutions in Maintenance Engineering & Asset management. The course was a great insight into looking at Maintenance Engineering in the overall context of the wider business. This lead to great learning and discussions while being judged by some of the top professionals in the field of Maintenance Engineering. I enjoyed my time at University of Manchester. The course over the three year I studied was enjoyable with the right balance of work & learning. At the present I am working on defining a decision making process to determine a PdM maintenance strategy with development of a fast track implementation plan. This is by leveraging Service Partners knowledge & expertise, while optimising the use of technologies and innovation to gain greater efficiencies within maintenance for the business.

I am a Maintenance Engineer at one of the largest integrated biopharmaceutical campuses in the world, manufacturing biopharmaceuticals, pharmaceuticals and vaccines products within the same facility. I have completed my MSc with distinction in Maintenance Engineering & Asset Management at the School of Mechanical, Aerospace and Civil Engineering, University of Manchester. I previously worked within the electronics industry for Hewlett-Packard (MFG) Ireland in both Engineering and production operations capacity in high volume manufacturing. I have a background as a Toolmaker with experience in jet engine maintenance and repair for Lufthansa Airmotive Ireland.


Project abstract

A major issue to address is whether an appropriate number of Engineering Maintenance Technicians for the maintenance of its facility. As part of the plant start-up projects the Maintenance Managers of the individual engineering sections set maintenance technician resource levels required for maintaining their sections of the plant. Their resource levels are based on individuals designing their sub organisations with no common approach or model to work from. Having reached the point of sustaining full production and it is not currently known if the number of Engineering Maintenance Technicians is the right size for the work required.

In 2008, organisational changes were agreed under the Single Site Structure, which has designed a flatter management structure. As part of the re-organisation the management team realised there is a need for a tool to model the Engineering Maintenance Technicians requirements based on investigating the factors and activities that require their time to maintain the plant. This is to ensure that the site has the right Maintenance Technicians headcount levels for the organisation.


Fig 1 The factors identified that use engineering technician's time.     Fig 2 Quantified "Hard factors" - hours, based on 24 maintenance technicians





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