Introduction:
Effective Planned & Predictive Maintenance 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 program 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 program from system development until a well-managed Maintenance system is in place and operational.
Targeted Groups:
The training is intended for:-
- Maintenance Personnel.
- Maintenance technicians.
- Maintenance engineers.
- Reliability engineers.
- Maintenance supervisors/managers.
- Operations Personnel.
- Operators who work closely with the equipment.
- Production supervisors/managers.
- Engineering Personnel.
- Reliability engineers.
- Management Personnel.
- Plant managers.
- Maintenance managers.
- Operations managers.
- Support Staff.
- Those involved in data analysis and interpretation.
- Administrative staff responsible for documentation and record-keeping.
- Cross-Functional Teams.
Training Objectives:
By the end of this course the participants will be able to:
- Understanding Maintenance Concepts.
- Equipment Knowledge.
- Maintenance Planning and Scheduling.
- Condition Monitoring Techniques.
- Predictive Maintenance Technologies.
- Maintenance Procedures and Best Practices.
- Safety and Compliance.
- Cross-Functional Collaboration.
- Performance Monitoring and Continuous Improvement.
Targeted Competencies:
- Equipment Knowledge.
- Maintenance Procedures.
- Condition Monitoring Techniques.
- Data Interpretation.
- Analytical Competencies.
- Problem-Solving.
- Data Analysis.
- Risk Assessment.
- Communication and Collaboration.
- Interdepartmental Communication.
- Documentation.
- Safety and Compliance.
- Continuous Improvement.
- Leadership and Management.
- Resource Management.
Course Content:
Unit 1: The Need for Maintenance:
- Failure Mode Effect & Criticality Analysis (FMECA):
- Causes of Failures.
- Likelihood & Severity of Failure - Risk Analysis.
- Reliability Centered Maintenance (RCM).
- 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 Construction:
- Installed Asset Base.
- Hierarchical Structure.
- Procedures and Plans.
- Resources:
- Dedicated Manpower.
- Contractors.
- Specialist Tools.
- Maintenance Strategies:
- Centralized/Decentralized.
- Life/Emergency/Corrective/Planned.
- Planned & Predictive.
Unit 3: The Planning Function:
- Roles & Responsibilities:
- The Planners.
- Job Initiators.
- Maintenance Trades.
- Job Planning:
- Planning Corrective Work.
- Integrate Planning with Procedures.
- Resource Leveling.
- Scheduling:
- Long Term Scheduling with Production.
- Medium- & Short-Term Scheduling.
- Planning Department Interfaces.
Unit 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.
Unit 5: Control of the Maintenance Process:
- CMMS Integration:
- Predictive Maintenance Interface.
- Optimizing 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.