Course details

Overview ?

Introduction

Effective Planned & Predictive Maintenance are critical for a successful company and an integral part of maintenance management strategies such as RCM, RBM TPM, and even 6-Sigma. This comprehensive 5-day programme has been designed to benefit both qualified new professionals as well as experienced professionals who may be involved in the rollout of a comprehensive Maintenance system or auditing an existing system. It covers all the steps required in developing a successful Planning & Predictive Maintenance programme from system development until a well-managed Maintenance system is in place and operational.

Seminar Objectives

Leading industrial organizations are evolving away from reactive (“fix-it-when-it-breaks”) management into predictive, productive management (“anticipating, planning, and fix-it-before-it-breaks”). This evolution requires well-planned and executed actions on several fronts.

Understand how world-class organizations solve common planning problems
Improve productivity through use of better, more timely information
Implement a practical and effective predictive maintenance effort
Improve consistency and reliability of asset information
Achieve more productive turnarounds
Optimize preventive and predictive maintenance strategies

Training Methodology

The seminar will be conducted along workshop principles with formal lectures, case studies and interactive worked examples. Relevant case studies will be provided to illustrate the application of each tool in an operations environment. Each learning point will be re-enforced with practical exercises. There will be ample opportunities for discussion and sharing experiences.

Organisational Impact

Select the most appropriate planning and predictive tools for Effective Maintenance
Integrate Predictive Maintenance into the Planning function
Introduce Critical Decision-Making Topics
Develop an effective system for controlling maintenance
Optimisation of the maintenance effort
Manage full and effective control of the maintenance budget

Personal Impact

The participants will:

Know and identify which equipment components should be part of your preventive maintenance plan
Know how to establish the most appropriate failure finding interval for protective devices – and how to come up with the failure risk of equipment that’s subject to condition-based maintenance
Know the right way to establish the optimal inspection frequency for equipment in continuous operation
Give you the tools needed to make data-driven decisions, which you can apply in your own environment and upon which you can rely to help you in developing appropriate programs
Know how to arrive at the economic life of an asset where its utilization declines as it ages

Who Should Attend?

Delegates should represent a wide range of personnel in the organization who are involved in, or dependent on, effective maintenance planning, scheduling and work control. These should include:

Maintenance Managers & Supervisors
Personnel designated as planners, or identified to become planners
Predictive Maintenance Technicians & Supervisors
Key leaders from each Maintenance craft
Key Operations Supervisors
Materials Management Managers/Supervisors
CMMS Administrator or key users

Programme Outline

Day 1 – The Need for Maintenance

Failure Mode Effect & Criticality Analysis (FMECA)
- Causes of Failures
- Likelihood & Severity of Failure – Risk Analysis
- Reliability Centred Maintenance (RCM)
Optimisation of Maintenance Decisions
- Failure Pattern Identification
- Statistical Analysis of Failures
- Weibull Analysis
Zero Base Budgeting
- Define the production requirement
- Define the maintenance requirement

Day 2 – Developing the CMMS

Database Construction
- Installed Asset Base
- Hierarchical Structure
- Procedures and Plans
Resources
- Dedicated Manpower
- Contractors
- Specialist Tools
Maintenance Strategies
- Centralised/Decentralised
- Life/Emergency/Corrective/Planned
- Planned & Predictive

Day 3 – The Planning Function

Roles & Responsibilities
The Planners
- Job Initiators
- Maintenance Trades
Job Planning
- Planning Corrective Work
- Integrate Planning with Procedures
- Resource Levelling
Scheduling
- Long Term Scheduling with Production
- Medium & Short Term Scheduling
- Planning Department Interfaces

Day 4 – Predictive Maintenance

Potential Failure Analysis (PFA)
- Integration of PFA with FMECA & RCM
- Understanding the P-F Interval
- Decide which Technologies to Apply
Vibration Analysis
- Detectable Faults
- Setup Parameters
- Monitoring & Protection
- On-Line or Off-Line
Supporting Technologies
- Infrared Thermography
- Passive Ultrasonics
- Oil Analysis

Day 5 – Control of the Maintenance Process

CMMS Integration
- Predictive Maintenance Interface
- Optimising PM Kit Usage with PdM
- Operational planning
Reporting
- Monthly PM & PdM reports for Management
- Financial Feedback Reports
- Budget Control
Key Performance Indicators
- Reliability & statistics – MTBF, Reliability etc.
- Work request backlog analysis
- Customer feedback analysis

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Day 3

Day 4

Day 5

Training Methodology

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