Maintenance & Reliability Best Practices : Certificate Course in Advanced Maintenance Management

Introduction

Leading industrial organizations are moving away from reactive (“fix-it-when-it-breaks”) maintenance into predictive and preventive maintenance (“anticipating, planning, and fix-it-before-it-breaks”) as part of a life cycle focused Asset Management approach. 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 training course introduces participants to the skills and knowledge areas of essential advanced maintenance management technologies, reliability best practices, and practical tools to drive down equipment life-cycle costs in practical ways. It emphasizes the most effective strategies, policies, tactics and practices needed to ensure the reliability, integrity and durability of physical assets through their life-cycle to achieve maximum Return On Investment (ROI).

This comprehensive training course will highlight:

• Asset Management: a business-like approach of Maintenance Management
• Using KPI’s and the balanced scorecard to Measure Performance
• Assessing Asset Management maturity and determine the roadmap for improvement
• The business case for Asset Management improvement - cost / benefit thinking
• Understanding risk and an introduction to a Risk Based Maintenance approach
• Life Cycle Management with aspects like Systems Engineering and RAMS requirements
• Life Cycle Costing
• The latest concepts and techniques of Predictive and Smart Maintenance
• Financial Concepts of Costs, Capital, Profit and Return On Investment
• The Model for Asset Healthcare
• Cost Impact of Equipment Failure and Degradation
• Proactive Practices and Tools to Reduce Maintenance Costs
• Failure Analysis to Focus Cost Reduction Efforts
• Work Management to Improve Resource Efficiency

Objectives

By the end of this training course, participants will be able to:

• Understand the basic principles of Asset Management as a framework for managing and optimizing maintenance
• Identify common maintenance Key Performance Indicators (KPIs) and develop the maintenance department scorecard
• Assess the organizational Asset Management maturity and develop a roadmap for improvement
• Examine the organizational and managerial considerations for highly effective Risk Based Maintenance
• Understand Life Cycle Management and the way Systems Engineering and RAMS could support this
• Determine the Life Cycle Costs of an asset
• Demonstrate the latest concepts and techniques with regard to Predictive and Smart Maintenance
• 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 analyse failure data to reduce repetitive failures
• Identify root causes of unanticipated failure costs
• Reduce resource costs through efficient work management practices

Training Methodology

This training course will be conducted along interactive training principles, delivered by means of a combination of instructor-led topic areas and class discussions. There will be a variance of lectures, practical individual and group exercises, examples, and pre-loaded templates for delegates to use as a reference for further study, research, or practice. Experiences from different areas will be discussed, culminating in a group-wise maintenance assessment resulting in a jointly developed shortlist of improvement actions.

Organisational Impact

The organisation will gain an understanding of the sources of maintenance costs, focus its resources on events that contribute most to costs, gather and structure failure data in a meaningful way, and eliminate defects that are driving costs.

Personal Impact

Participants will understand behavior and events driving costs, how poor reliability impacts the cost equation, how to implement PM programs and root cause analysis to eliminate defects, and how to apply best practice work management.