Course details

Overview ?

INTRODUCTION

This 10-day programme initially looks at all of the core maintenance management disciplines that support effective work planning, scheduling and work control. The second week builds on the foundation knowledge introduced during the first week by introducing participants to Maintenance Auditing and Benchmarking. These key tools can be used to ensure the core disciplines are maintained, to drive improvement, identify best practices, and assist with the formulation of strategies.

This programme will cover:

Modern Maintenance Management Practices
Maintenance Policies and Logistics Planning
Failure Management
Work Planning, Scheduling and Control
Information and Performance Management
Maintenance Auditing & Benchmarking
Performance Measurement

WHO SHOULD ATTEND?

Professionals who are involved in maintenance planning, scheduling and work control, including planners and users of CMMS. Also, any stakeholders in the Work Planning function would benefit from attending this programme

PROGRAMME 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.

You will:

Identify planning best practices and key elements for taking action on them
Understand how world-class organizations solve common planning problems
Evaluate your practices compared to those of others
Improve the use of your information and communication tools
Improve productivity through use of better, more timely information
Create and preserve lead-time in work management and use it for planning and scheduling resources
Improve consistency and reliability of asset information
Achieve more productive turnarounds
Optimize preventive and predictive maintenance strategies
Audit your maintenance operations
Learn how to conduct a benchmarking study
Use the results to develop and improvement strategy
Establish Auditing and Benchmarking as a key element of the maintenance strategy

The programme will impart an understanding of how such techniques can be applied as part of a broad systematic approach to proactively managing and improving maintenance

TRAINING METHODOLOGY

Facilitated by experienced maintenance specialists, this programme will be conducted as highly interactive work session, encouraging participants to share their own experiences and apply the programme material to real-life situations. Case studies from different industries will be investigated. Programme size will be limited to 30 delegates in order to stimulate discussion and efficiency of subject coverage. Each delegate will receive an extensive reference manual, as well as case studies, while worked out solutions will be handed out to the delegates on conclusion of group discussions.

To ensure the concepts introduced during the programme are understood, they will be reinforced through a mix of learning methods, including lecture style presentation, open discussion, case studies, simulations and group work.

PROGRAMME SUMMARY

Week 1 of the programme deals with the essential principles and techniques for effective maintenance management, covering proven techniques for the development of an effective maintenance plan, the planning, scheduling and control of maintenance work, and management reporting and analysis

Week 2 of the programme covers the use and application of a standardised maintenance management audit methodology, consistent with the recognised maintenance excellence framework, to assess the current state of maintenance management strategy implementation, and identify opportunities for improvement. Similarly, participants will learn how to plan, conduct and interpret the results of a maintenance benchmarking study to drive improvement of their maintenance management systems.

PROGRAMME OUTLINE

DAY 1 - MODERN MAINTENANCE MANAGEMENT PRACTICE IN PERSPECTIVE

Maintenance Practice in Perspective
- Maintenance in the Business Process
- Evolution in Maintenance Management
- The Contribution of Maintenance to the achievement of the Business Objectives
- Business, Operations and Maintenance Key Performance Area
- The Maintenance Objective
- Roles and Accountability

DAY 2 - MAINTENANCE POLICIES AND LOGISTICS PLANNING

Equipment Classification and Identification
- Functional Location
- Equipment Type Classification
- Equipment Identification
- Part Number and Bill of Material
- Documentation Structures
- Document Identification and Classification
Maintenance Management Policies
- Equipment Criticality Grading
- Job Record Policy
- Job Information Requirements
- Principles of Work Order Design
- Maintenance Work Prioritisation
Maintenance Logistics Planning
- Logistic Support Analysis
- Maintenance Task Detail Planning
- Maintenance Work Estimating
- Maintenance Levels
- Support Documentation
- Support Equipment
- Personnel and Organisation

DAY 3 - FAILURE MANAGEMENT PROGRAMME DEVELOPMENT

Failure Modes, Effects and Consequences
- Equipment Functions and Performance Standards
- Functional Failures
- Failure Modes
- Failure Effects
- Consequences of Failure
- Failure Management Policies
- Age Related Failure Patterns
- Random Failure Patterns
- Routine Restoration and Discard Tasks
- Routine Condition-based Tasks
- Failure-finding Tasks
- The application of RCM in the Development of Failure Management Policies
- Implementing Failure Management Policies
- Proposed Routine Maintenance Tasks
- Categorising and structuring Routine Maintenance Tasks
- Corrective Maintenance Planning
- Logistic Requirements Planning

DAY 4 - WORK PLANNING, SCHEDULING AND CONTROL

Definition of Notifications, Defects, Deviations
Notification Process, Roles and Principles
Prioritising Notifications
Weekly Master Schedule
- Master Schedule Objectives
- Categorise the Outstanding Workload
- Determine Resource Availability
- Determine Equipment Non-utilisation Profile
- Develop Draft Master Schedule
- Conduct Master Schedule Review Meeting
- Final Master Schedule and Implementation
- Backlog Management

DAY 5 - INFORMATION AND PERFORMANCE MANAGEMENT

Management and Information
- Information and Control
- Management Levels and Information
Performance Indicators
- Performance Indicators
- Workload Performance Indicators
- Planning Performance Indicators
- Effectiveness Performance Indicators
- Cost Performance Indicators
- Management Reports

DAY 6 - INTRODUCTION AND FOUNDATION CONCEPTS

Introduction to Auditing and Benchmarking
Introduction to Maintenance Processes
Approaches to Maintenance Management and Improvement
Introduction to Maintenance Management Benchmarking Frameworks

DAY 7 - MAINTENANCE AUDITING

Maintenance Performance Measures and Metrics
The Maintenance Auditing Process
Maintenance Auditing Methodology
Conducting a Maintenance Audit
Maintenance Audit Simulation Case Study

DAY 8 - MAINTENANCE AUDITING AND BENCHMARKING

Maintenance Audit Simulation Case Study
Using Maintenance Audit Results to Plan Improvement Strategies
Introduction to Benchmarking
The Maintenance Benchmarking Process
Maintenance Benchmarking Methodology
Benchmarking Tools and Techniques

DAY 9 - MAINTENANCE BENCHMARKING AND PERFORMANCE MEASUREMENT

Benchmarking Tools and Techniques (continued)
Designing and Preparing for a Benchmarking Study
Selecting Benchmarking Partners
Preparing for an conducting the benchmarking visit
Reporting results of Benchmarking and Auditing Studies
The DMG Analysis – Advanced Benchmarking Conducting a Maintenance Benchmarking Study

DAY 10 - AUDITING, BENCHMARKING AND MAINTENANCE IMPROVEMENT

Benchmarking Simulation Case Study
Integrating Benchmarking resulting into improvement and objective setting processes
Integrating Maintenance Auditing and Benchmarking into the Performance Measurement System to establish improvement objectives and strategies
Review of Best Practice Benchmarks and Case Studies
Conclusion