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RMA - 09

5 days

Doha

4 June, 2023

11900 QAR

Predictive Maintenance and Condition Monitoring Techniques

Course Overview:

The maintenance philosophies are one of the major parts in our era. The definition between Maintenance and Repair issues is one of the major concerns. The application of the developed maintenance techniques such as the RPN and the FMEA techniques together with the troubleshooting techniques will be discussed.

In addition to an increase in reliability, more money is saved in comparison to the cost of a program just using reactive maintenance, Participants indicate that this savings can amount to as much as 12% to 18% on the average. Depending on a facility’s current maintenance practices, present equipment reliability, and facility downtime, there is little doubt that many facilities are purely reliant on reactive maintenance. By implementing a proper preventative maintenance program, they could save much more than 18%.

Course Objectives:

Upon completion of this course, the trainees will be aware and understanding of the following:

Develop, implement and supervise the preventive and predictive maintenance program
Implement the latest techniques and management styles of leading facilities and maintenance management practices
Optimize the effectiveness of maintenance, by using sophisticated techniques and methods, to economize time, money and resources
Prevent and limit equipment failures, and rework to improve the equipment’s overall effectiveness and reliability
Decrease downtime and increase profit for their organization

Who Should Attend?

This course is designed for all Maintenance Managers/Engineers, Supervisors and Planning Engineers. It is also suitable for those who are in operations, engineering and purchasing/materials divisions and who would like to acquire an understanding of how the quality of the maintenance function affects their department, and their organization’s bottom-line.

Course Content:

Module (01) Maintenance overview

What is maintenance?
Building a best in class asset register
Formulating the maintenance policy
Defining maintenance standards and allocation of resources
Applying maintenance strategies

Module (02) Common issues in an organization

Lack of accountability
Resource level issues
Work requests with insufficient information or duplicated
Importance of time writing daily
Technical history retention
KPI reviews – how often and why

Module (03) Computerized Maintenance Management System (CMMS) set-up

CMMS set-up
Criticality assignment SCE
Class and classification assessment and allocation
Defining asset register systems
Allocation of main work centers
Cost center assignment(s)
Bills of Material (BOMs) advantages

Module (04) Work identification and requesting

Work preparation: what is required and why
Equipment assignment to the correct level
Assigning prioritization – the benefits in using prioritization
Best-in-class information required through Corrective Maintenance – Predictive Maintenance (CM-PM) work order(s)
Roles and responsibilities for work preparation

Module (05) Work planning and estimating

Reviewing past history and the benefits to work planning
Allocation of correct resources and hours
Identifying materials using Bills of Material (BOMs)
Allocation of external resources with or without Service Level Agreements (SLA)
Consider building relationships between activities within work order operations
Pre-scheduling through criticality – prioritization

Module (06) Completion and work control

Updating the future maintenance plans(s) and asset register through technical history feedback
Review of estimated versus planned versus actual costs
Review of man-hours expended versus estimated
Material usage – Question were any materials not used returned to stock?
Correctly signing off work order/work request through the CMMS system

Module (07) Maintenance replacement decisions

Component replacement procedures
Age-based replacement policy
Analysis of component failure data
Using Weibull parameters
Life-cycle costing

Module (08) Downtime reduction

Tracking downtime
Personnel training
Importance of feedback from employees
Outsourcing considerations
Considering using Overall Equipment Effectiveness (OEE)

Module (09) Performance reporting

Primary reporting Key Performance Indicators (KPIs)
Secondary reporting KPIs
Leading and lagging KPIs

Module (10) Action plan

Management of Change (MOC) process
Continuous Improvement (CI) techniques

Predictive Maintenance and Condition Monitoring Techniques

TRAINING PLAN FORM