Implementing Effective Preventive and Predictive Maintenance Programmes

courses Syllabus

Introduction

Effective Planned & Predictive Maintenance are indispensable for a thriving company and are integral to maintenance management strategies like RCM, RBM TPM, and even 6-Sigma. This comprehensive 5-day program is designed to benefit both qualified new professionals and experienced professionals involved in implementing or auditing maintenance systems. It covers all steps required in developing successful Planning & Predictive Maintenance programs from system development to operational implementation.

Objectives

Leading industrial organizations are transitioning from reactive ("fix-it-when-it-breaks") management to predictive, proactive management ("anticipating, planning, and fixing-it-before-it-breaks"). This evolution necessitates well-planned and executed actions on multiple fronts:

• Understand how world-class organizations tackle common planning issues
• Enhance productivity through better, timely information usage
• Implement a practical and effective predictive maintenance effort
• Improve consistency and reliability of asset information
• Achieve more productive turnarounds
• Optimize preventive and predictive maintenance strategies

The Contents

Day 1 - The Need for Maintenance

• Failure Mode Effect & Criticality Analysis (FMECA)
• Causes of Failures
• Likelihood & Severity of Failure – Risk Analysis
• Reliability Centred 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
• Centralised/Decentralised
• 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 Levelling
• 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
• Optimising 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