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.

Course Objectives

By the end of this course, 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.

Target Audience

This course is designed for:

• 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.

Course Outline

Day 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.

Day 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.

Day 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.

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.
• 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.