Implementing Effective Preventive And Predictive Maintenance Programmes

Category: Aci Code Requirements And Specifications For Concrete Design, Construction And Repair Training

Course Description

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

Course Outline

  • 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
  • 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
  • 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
  • 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
  • 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