Implementing Effective Preventive and Predictive Maintenance Programmes

Courses Syllabus

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