Best Preventive Maintenance Management Practices Technology & Management Practices

Overview:

Introduction:

Effectively planned Preventive & Predictive Maintenance which is integrated with the workflow is 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 training course 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 & Asset Management process or auditing an existing process. It covers all the steps required in developing a successful Preventive & Predictive Maintenance Program from failure behavior and finding the right preventive maintenance task until a well-managed preventive & predictive maintenance program, fully integrated with the workflow and the CMMS.

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

Course Objectives:

At the end of this course, the participants will be able to:

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

Targeted Audience:

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

Course Outlines:

Unit 1: The Need for Maintenance:

• Maintenance & Asset Management as a business process
• Risk-Based Maintenance (RBM)
  • Causes of Failure
  • Likelihood & Severity of Failure - Risk Analysis
  • Failure Mode Effect & Criticality Analysis (FMECA)
  • Choosing the (preventive) maintenance tasks
• Optimization of Maintenance Decisions
  • Failure Pattern Identification
  • Statistical Analysis of Failures
  • Weibull Analysis
• Zero Base Budgeting
  • Define the production requirement
  • Define the maintenance requirement

Unit 2: Developing the CMMS:

• Database & structure
• CMMS & workflow
• CMMS & Maintenance Strategies
• Asset register
• Configuration management

Unit 3: The Planning Function:

• The maintenance workflow and how it relates to the preventive maintenance strategy
• Roles & responsibilities in work preparation, planning, and scheduling
• Principles of work preparation & planning
• Principles of scheduling
• Network planning

Unit 4: Predictive Maintenance:

• Potential Failure Analysis (PFA)
  • Integration of PFA with FMECA & RBM
  • Understanding the P-F Interval
  • Decide which Technologies to Apply
• Predictive maintenance technologies
  • Vibration analysis
  • Visual inspection
  • Infrared Thermography
  • Temperature-sensitive labels
  • Megger tests
  • Ultrasonics
  • Oil analysis

Unit 5: Control of the Maintenance Process:

• Implementation stages of preventive & predictive maintenance strategies
• CMMS integration
• Reporting – use of (Key) Performance Indicators
• Case study