INTRODUCTION

Lower revenues due to lower commodity prices have placed equipment life-cycle costs under the management spotlight like never before. Maintainers are faced with the challenge to deliver the same levels of equipment safety, reliability and availability with smaller budgets. This  Maintenance Engineering training course on Maintenance & Reliability Best Practices introduces the practical tools and practices that organizations need to adopt to drive down their equipment life-cycle costs in practical ways

This Maintenance Engineering training course emphasizes the most effective strategies, policies, tactics and practices that are needed to ensure the reliability, integrity and durability of the physical assets through their life-cycle.

Objectives

At the end of this training course, you will learn to:

Understand the concepts of costs, capital, profit and ROI

Understand the cost impact of unanticipated failure

Apply proactive policies to reduce future maintenance costs

Structure and analyze failure data to reduce repetitive failures

Identify root causes of unanticipated failure costs

Reduce resource costs through efficient work management practices.

Benefit of this course

Gain an understanding of the sources of maintenance costs

Be able to focus its resources on the events that contribute most to costs

Gather and structure failure data in a meaningful way

Eliminate defects that are driving costs

Understand the behavior and events that are driving costs

Understand how poor reliability is a major factor in the cost equation

Implement a PM program to improve reliability

Implement root cause analysis to eliminate defects

Apply best practice work management to ensure early detection and correction of defects

Course Outline:

Day 1

Equipment Life-cycle Cost Introduction

Definitions of Reliability, Maintenance & Asset Management

The Concept of Costs, Capital, Profits and Return On Investment

The Asset Healthcare Model

Key Areas of Asset Management

Open Discussion Sessions

Day 2

Cost Factors and Causes

The Real Cost of Unanticipated Failure

Asset Performance Standards

The Forms of Asset Failure and Degradation

The Causes and Nature of Asset Failure and Degradation

The Effects, Cost and Risks of Asset Degradation

Day 3

Breaking the Cycle of Degradation and Costs

Programmed Maintenance

Programmed Maintenance Intervals

Condition-based Maintenance Intervals

Implementing Optimized PM Programs

Optimizing Spares to Support the Maintenance Program

Day 4

Cost Reduction through Defect Elimination

Failure Data Collection and Analysis

The Impact of Chronic Failures vs. Intermittent Failures

Focus Improvement through Pareto Analysis

Quantify losses in Life Cycle Terms

Rigorous Root Cause Analysis Techniques

Discussion of Software and Templates to Support Analysis

Day 5

Work Management converts Strategy to Practice

Work Identification and Defect Reporting

The Importance of Backlog

Planning for Quality and Reliability

Capacity Planning

Scheduling for Efficiency

Work Logistics and Preparation

Checklists and Practical Aspects Work Quality Control

Final Discussion and Evaluation