By the end of this programme, participants will:
- Understand the key principles and best practices of maintenance and reliability, and their importance in improving operational performance.
- Be able to apply Reliability-Centered Maintenance (RCM) methodologies to optimize asset life and minimize unplanned downtime.
- Develop strategies for implementing preventive and predictive maintenance programs that enhance equipment reliability and reduce costs.
- Gain the skills to perform root cause analysis (RCA) and identify the most effective corrective actions to improve equipment performance.
- Learn how to evaluate and select the appropriate maintenance strategies based on asset criticality and operational risk.
- Develop an understanding of the role of technology and data analytics in modern maintenance and reliability practices, including the use of CMMS and IoT solutions.
DAY 1
Introduction to Equipment Life-Cycle Cost and Asset Management
- Definitions of Reliability, Maintenance & Asset Management
- Understanding the key concepts of reliability, maintenance strategies, and asset management
- The importance of integrating maintenance practices with business goals
- Key differences between maintenance types: corrective, preventive, predictive, and proactive
- The Concept of Costs, Capital, Profits, and Return On Investment (ROI)
- Analyzing the financial aspects of maintenance decisions
- Calculating ROI for maintenance investments and reliability improvements
- Evaluating the cost of asset ownership and maintenance over its life cycle
- The Asset Healthcare Model
- Introducing the Asset Healthcare Model for managing asset performance
- Key metrics for assessing asset health and identifying risks
- Establishing a proactive asset care culture within the organization
- Key Areas of Asset Management
- Strategic asset management: aligning asset management with company goals
- Maintenance planning, scheduling, and optimization
- Asset lifecycle management: from procurement to disposal
- Integrating sustainability into asset management practices
- Open Discussion Sessions
- Sharing real-world experiences and challenges related to maintenance and asset management
- Group discussion on best practices in the field and strategies for overcoming common obstacles
DAY 2
Cost Factors, Failure Causes, and Asset Performance Standards
- The Real Cost of Unanticipated Failure
- Understanding the direct and indirect costs of unplanned downtime
- Analyzing the impact of asset failure on production, safety, and profitability
- Quantifying the long-term financial implications of poor maintenance practices
- Asset Performance Standards
- Defining performance standards for key assets to ensure reliability
- Creating benchmarks for asset performance and establishing improvement goals
- The role of performance standards in setting maintenance priorities
- The Forms of Asset Failure and Degradation
- Classifying different types of asset failure: mechanical, electrical, and structural
- Identifying early warning signs of asset degradation and failure
- Understanding the impact of aging equipment on performance
- The Causes and Nature of Asset Failure and Degradation
- Exploring the root causes of asset failure: design flaws, material defects, and external factors
- Identifying internal and external contributors to asset degradation
- Preventing failure through regular inspections, analysis, and effective maintenance
- The Effects, Cost, and Risks of Asset Degradation
- Analyzing the financial impact of asset degradation over time
- Risk assessment techniques for identifying critical assets at risk of failure
- Mitigating risks through proactive maintenance and condition monitoring
DAY 3
Breaking the Cycle of Degradation and Costs
- Programmed Maintenance (PM) Strategies
- Developing a structured and effective PM program to reduce unplanned downtime
- Understanding the role of PM in extending asset life and improving reliability
- Key elements of a successful PM strategy: tasks, intervals, and execution
- Programmed Maintenance Intervals
- Determining the appropriate frequency of scheduled maintenance activities
- Balancing maintenance frequency with asset reliability and performance
- Evaluating the effectiveness of existing maintenance intervals and adjusting as necessary
- Condition-based Maintenance (CBM) Intervals
- Understanding the principles and implementation of CBM
- Using real-time data to predict maintenance needs based on asset condition
- Developing effective CBM programs using condition monitoring tools and sensors
- Implementing Optimized PM Programs
- How to optimize PM schedules to minimize downtime and maintenance costs
- Strategies for continuous improvement in PM processes through data analysis and feedback
- Case studies on successful optimization of PM programs in different industries
- Optimizing Spares to Support the Maintenance Program
- Developing strategies for spare parts management to avoid stockouts and overstocking
- Evaluating the criticality of spare parts and optimizing inventory levels
- Leveraging technology and systems to improve spare parts tracking and procurement
DAY 4
Cost Reduction through Defect Elimination and Root Cause Analysis
- Failure Data Collection and Analysis
- Collecting and analyzing data from failed components to identify trends and patterns
- Using data to develop insights and inform decision-making
- Tools for tracking failure data and creating reports for performance monitoring
- The Impact of Chronic Failures vs. Intermittent Failures
- Identifying the root causes of chronic vs. intermittent failures
- Understanding the financial impact of chronic failures on maintenance costs and downtime
- Implementing solutions to address chronic failure modes and improve reliability
- Focus Improvement through Pareto Analysis
- Applying Pareto Analysis to prioritize maintenance efforts and focus on high-impact failures
- Identifying the “vital few” causes that contribute to most failures
- Developing corrective actions based on Pareto outcomes
- Quantifying Losses in Life Cycle Terms
- Calculating the life cycle cost of asset failures and maintenance interventions
- Identifying hidden costs of poor maintenance practices and failures
- Assessing the financial impact of delayed maintenance and underperforming assets
- Rigorous Root Cause Analysis Techniques
- Advanced methods for performing root cause analysis (RCA), including 5 Whys and Fishbone Diagrams
- How to systematically identify the underlying causes of recurring issues
- Implementing corrective actions and preventive measures based on RCA findings
- Discussion of Software and Templates to Support Analysis
- Exploring software tools and templates that facilitate failure analysis and maintenance reporting
- Introduction to common software solutions for asset management and maintenance optimization
- How to use technology to streamline analysis and reporting processes
DAY 5
Work Management: Converting Strategy into Practice
- Work Identification and Defect Reporting
- Developing clear processes for identifying maintenance work and defect reporting
- Utilizing maintenance management systems (CMMS) to log and track defects
- Prioritizing defects based on criticality and operational impact
- The Importance of Backlog Management
- Understanding the impact of backlog on maintenance efficiency and asset reliability
- Developing strategies for managing and reducing maintenance backlog
- Ensuring timely completion of high-priority tasks to prevent backlog buildup
- Planning for Quality and Reliability
- The role of planning in ensuring maintenance tasks are executed with quality and reliability
- How to set quality standards and ensure consistent performance across all maintenance activities
- Measuring the effectiveness of maintenance planning through post-task evaluations
- Capacity Planning and Resource Allocation
- Determining the resources (human, equipment, and financial) needed for maintenance tasks
- Techniques for balancing workload and ensuring capacity for high-priority tasks
- Managing resource availability to minimize delays in maintenance work
- Scheduling for Efficiency
- Strategies for optimizing maintenance schedules to minimize downtime and improve resource utilization
- Tools and techniques for efficient scheduling, including Gantt charts and scheduling software
- Balancing scheduled work with emergency repairs and unforeseen maintenance tasks
- Work Logistics and Preparation
- Ensuring all necessary materials, tools, and personnel are available before maintenance work begins
- Preparing for scheduled work through effective logistics planning
- Streamlining work processes to reduce delays and increase productivity
- Checklists and Practical Aspects of Work Quality Control
- Developing checklists and standard operating procedures (SOPs) for maintenance tasks
- Implementing quality control measures to ensure consistent and high-quality maintenance outcomes
- Monitoring work quality and implementing corrective actions where necessary
- Final Discussion and Evaluation
- Recap of key concepts and takeaways from the course
- Group discussion on challenges and solutions to implementing best practices in maintenance and reliability
- Participant evaluation of the course content and feedback for future improvements
