Course Outline
Module 1: Maintenance Management Best Practices
Day One: An Overview of Key Maintenance Work Processes
- Introduction to Maintenance Management
- Definitions of key terms
- Types of Maintenance – Reactive, planned and improvement jobs, Preventive and Proactive
- A comprehensive maintenance control system
- Priorities when implement a systematic preventative maintenance program
- Case Studies Learning from Failures
Day Two: Maintenance Performance Measures Systems & Human Factors
- Developing Maintenance Key Performance Indicators
- The Overall Equipment Effectiveness (OEE)
- Total Productive Maintenance (TPM)
- The Concept of ‘Ask Why 5 times!’
- Teamwork and Continuous Improvement
- Case Studies from Different Industries
Day Three: Key Terms and techniques in Reliability Systems and Maintenance Management
- What is Reliability, Redundancy, Failure, Maintainability and Availability?
- Mean Time Between Failure (MTBF) & Mean Time to Repair (MTTR)
- The Concept of the Bathtub Curve
- Failure Mode and Effects Analysis (FMEA)
- Fault Tree Analysis (FTA)
- Reliability Centered Maintenance (RCM)
Day Four: Maintenance Management Systems
- Computerized maintenance Management Systems
- Selection of Appropriate Maintenance Strategy
- The Decision-Making Grid (DMG)
- Integration of TPM, RCM and CBM
- Case Studies from Different Industries
- The Concept of Benchmarking
Day Five: Maintenance Planning and Control
- Project Management in Maintenance & Shutdowns
- Phases of Projects
- Project management tools for planning
- The concept of critical path method (CPM)
- Resource Allocation
- Project Crashing
Module 2: Maintenance, Reliability and Asset Management Technology Best Practices
Day Six: Failure of Machines and Inspection Based Failure Analysis - Causes of Machinery Failure in Rotating Equipment
- Cavitation in pumps.
- Tripping of turbines.
- Surging in compressors.
- Wear Mechanisms : Fatigue, Fretting, and Corrosion.
- Fundamental Machine Problems: Balance Problems, Alignment Problems, Machinery Mounting Problems
- Fundamentals of maintenance and asset management.
Day Seven: Failure Analysis and Reliability
- Elementary Statistics and standards.
- Reliability Models
- Learning from major failures case studies in process industries.
- Learning from major failures case studies in oil and gas industries.
- Root cause analysis and extractions of specific and generic lessons.
Day Eight: Statistical Failure Analysis and Reliability
- Further reliability definitions and standards.
- Hazard function and bath tub curve.
- Weibull analysis.
- Case studies from rotating equipment.
- Case studies of major failures in other industries and lessons learned.
Day Nine: Condition Based Maintenance
- General Purpose
- What is Vibration
- Thermal Monitoring
- Lubricant Monitoring
- The Essentials of Vibration Monitoring
Day Ten: Decision Analysis in Asset Management
- Main criticism of existing management of computerised maintenance systems.
- The Asset Management framework.
- The decision making grid approach.
- Selection of appropriate maintenance strategies.
- Integration of RCM, TPM, and CBM approaches