Start Date : 16 Mar ,2025
End Date : 20 Mar ,2025
Duration : 5 Days
Overview:
Achieving excellence in maintenance and reliability is the aim of every organization that depends on its physical assets to achieve business objectives. Lower profit margins have made reducing maintenance costs imperative to the survival of many organizations. The overall cost of asset ownership is closely tied to the outcomes of reliability, durability and longevity of physical assets. This training course is about developing and implementing the strategy and tactics that deliver the outcomes we need.
This Excellence in Maintenance and Reliability Management training course starts with the key aspects that lay the foundations and cornerstones of an effective maintenance function. It introduces reliability strategies such as FMECA, TPM, RCM and RCFA to highlight their costs and benefits. The Excellence in Maintenance and Reliability Management training course will then demonstrate how these strategies are used to derive the different maintenance tactics of predictive, preventive, detective and repair-after-failure maintenance tactics.
Course Objectives:
- Compare their current maintenance strategies to industry best practice
Understand the benefits and costs of alternative maintenance strategies
Define maintenance strategies for a specific system using a decision support process and tools
Analyze failures and determine the root causes using the tools and templates provided
Implement reliability improvement methodologies correctly
Prepare maintenance schedules and procedures for implementation
Course Content:
1. Introduction to Maintenance and Reliability Management
- The cost and risk of equipment failure
- Pillars of excellence in maintenance
- Best practice reliability and maintenance processes
- Overview of FMECA, TPM, RCM, RBI, and RCFA
2. Establish a Framework for Reliability
- Build a competent team to drive reliability in each area
- Asset identification, classification, and criticality grading
- Define asset performance and efficiency standards
- Anticipate the physical causes of failure and degradation
- Anticipate the human causes
- Analyze the effects and quantify the risks
- Practical application of failure and risk analysis
3. Failure Management Strategy Development
Risk-based approaches to failure management
Select proactive maintenance tactics on the basis of costs and risks
Preventive maintenance tasks and intervals
Predictive maintenance tasks and intervals
Failure detection and function testing tasks and intervals
Human error reduction through equipment, procedural and skill upgrades
Repair-after-failure strategies
Practical application and open discussion sessions of case study
4. Failure Management Strategy Implementation
Aggressive defect reporting to feed the backlog
Plan for quality, time and safety
Budget for spare parts and make stocking decisions
Schedule maintenance to minimize operational downtime
Use appropriate metrics to drive defect elimination
Practical application and open discussion sessions
5. Root Cause of Failure Analysis
Failure reporting analysis and corrective action system requirements
Use failure data and Pareto analysis identify and stratify improvement opportunities
Types of evidence, preservation, and use
Organize the RCFA and apply the process
Practical RCFA case study using a MS Excel-based tool
Review of failure forensic techniques
Targeted Audience:
- Reliability Engineers
- Maintenance Planners
- Maintenance Supervisors
- Maintenance Engineers
- Operations and Process Team Leaders
