Predictive Maintenance

Overview:

Introduction:

The maintenance of physical assets can no longer be treated as an 'engineering problem'. The competitive environment in which a business operates requires an approach that integrates the operational objectives of the business and the life-cycle objectives of the physical assets.

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.

Our highly interactive program is designed to provide the workforce with essential physical asset management skills, gain a clear understanding of their role, and work more effectively within a team environment. "Maintenance is not only part of the production process, it must be planned into the production process."

Course Objectives:

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

• 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 the 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

Targeted Audience:

• Maintenance Managers
• Maintenance Engineers
• Maintenance Supervisors
• Planning Engineers
• Operations Professionals
• Engineering and Purchasing Staff
• Materials Divisions

Course Outlines:

Unit 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
  • Roles and Accountability

Unit 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
• Logistic Support Analysis
• Maintenance Task Detail Planning
• Maintenance Work Estimating
• Maintenance Levels
• Support Documentation
• Support Equipment
• Personnel and Organisation
• Maintenance Logistics Planning

Unit 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
• Proposed Routine Maintenance Tasks
• Categorizing and structuring Routine Maintenance Tasks
• Corrective Maintenance Planning
• Logistic Requirements Planning
• Implementing Failure Management Policies

Unit 4: Work Planning, Scheduling, and Control

• Definition of Notifications, Defects, Deviations
• Notification Process, Roles, and Principles
• Prioritizing Notifications
• Weekly Master Schedule
  • Master Schedule Objectives
  • Categorize 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

Unit 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