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.
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
The Contents
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
