Maintenance Planning, Scheduling, Management and Work Control
Engineering and Technical Programs
Introduction
Maintenance planning, scheduling and work control is the most important function of a maintenance department but for many years, industry experts have pointed to the low productivity levels in maintenance departments of many companies around the world. Several studies and survey results reported at major Maintenance and Reliability conferences have confirmed this. A maintenance department can be far more productive in so many ways, becoming proactive instead of responding to emergencies like fire departments. Maintenance departments should be performing preventive and condition-based maintenance tasks, participating in process improvement projects, and working on capital improvement initiatives. Maintenance workers can upgrade their skills by attending Maintenance Planning training courses, train others, and educate operators to run the assets properly to minimize errors. In essence, good planning and scheduling avoids delays and minimizes wait time, other wasteful activities, and non-productive work. Maintenance Planning, Scheduling and Work Control is a disciplined approach both for utilizing maintenance resources effectively and for executing maintenance tasks efficiently.
- Covers all the fundamentals
of Maintenance as well as the advanced techniques of maintenance planning,
scheduling, and monitoring.
- Focuses on basic concepts of
preventive and predictive maintenance and scheduling procedures for
machinery troubleshooting.
- The understanding of
possible reasons leading to machinery failure and how to prevent it.
- Understand all the
fundamentals of Maintenance.
- Understanding as well as the
advanced techniques of maintenance planning, scheduling, and monitoring.
- Learn the basic concepts of
preventive and predictive maintenance and scheduling procedures for
machinery troubleshooting.
- The understanding of
possible reasons leading to machinery failure and how to prevent it.
- Understand the need for and
purpose of proactive maintenance management.
A highly interactive combination of lecture and discussion sessions will be managed to maximize the amount and quality of information, knowledge and experience transfer. The sessions will start by raising the most relevant questions, and motivate everybody finding the right answers. The attendants will also be encouraged to raise more of their own questions and to share developing the right answers using their own analysis and experience.
Percentage of Delivery Methodologies
- 35% Presentation
- 30% Group & Individual Exercises
- 25% Case Studies
- 10% Active Movies and Simulation
Course Outline
Day 1:
Fundamentals of maintenance
- Maintenance
Definitions
o
Planned Maintenance
o
Preventive – Proactive-
Predictive, Conditional Monitoring
o
Turnaround
·
Maintenance Philosophy
o
What is to be maintained?
o
Why to do maintenance?
o
Who will execute maintenance?
o
Where to do maintenance?
o
When maintenance to be executed?
o
How to do maintenance?
Day 2:
Advanced techniques in maintenance planning, scheduling, and monitoring
·
Objective.
- Optimizing the
reliability, efficiency, and cost-effectiveness of maintenance activities
in industrial settings.
·
Advanced techniques tools:
ü
Reliability-centered
Maintenance (RCM).
RCM critical components and systems - - Techniques
include Failure Mode and Effects
Analysis (FMEA) and Root Cause
ü
Condition-Based
Maintenance (CBM).
CBM performance and condition… Predictive maintenance techniques, such
as vibration analysis, thermography, and oil analysis.
Day 3:
Planning & Scheduling for Maintenance Strategies and Techniques
- Elements of maintenance tasks and programs.
- Preventive Maintenance
ü
Establishing a Preventive
Maintenance Program.
ü
Elements of Preventive
Maintenance Procedure.
ü
Preventive Maintenance
Considerations
- Condition Based Maintenance: Concept, Techniques & Application
ü
Establishing an effective
Condition Based (Predictive) Maintenance Program.
ü
Planning & Scheduling PDM
activities.
- Computerized Maintenance Management System (CMMS) & EAM.
Day 4:
Machinery reasons for machinery failure and preventive strategies.
- Lack
of Maintenance.
- Improper
Operation.
- Component
Wear and Tear.
- Environmental
Factors.
- Overloading
or Overuse.
Machinery
reasons for machinery failure and preventive strategies continue.
- Design
Flaws or Deficiencies
- Electrical
and Power Issues
- Human Error
- Age and Wear-Out.
Day 5:
Failure Modes, Effects and Consequences
o
Equipment Functions and
Performance Standards
o
Functional Failures
o
Failure Modes
o
Failure Effects
o
Consequences of Failure
·
Failure Management Policies
·
Age-Related Failure Patterns
·
Random Failure Patterns
·
Routine Restoration and Discard Tasks
·
Routine Condition-based Tasks
·
Failure-finding Tasks
·
The application of RCM in the Development of Failure Management Policies.