Excellence in Maintenance and Reliability Management
Excellence in Maintenance and Reliability Management
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
WHO SHOULD ATTEND?
- Reliability Engineers
- Maintenance Planners
- Maintenance Supervisors
- Maintenance Engineers
- Operations and Process Team Leaders
COURSE OUTLINE:
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
Establish 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
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
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
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