The primary objective of every organization that relies on its physical assets to achieve business goals is to attain excellence in maintenance and reliability. With decreasing profit margins, reducing maintenance costs has become crucial for the survival of many organizations. The overall cost of asset ownership is directly linked to the outcomes of reliability, durability, and longevity of physical assets. This training course focuses on the development and implementation of strategies and tactics that yield the desired outcomes.

Course Objectives:

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

· 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?

Personnel who should attend are:

Reliability Engineers
Maintenance Planners
Maintenance Supervisors
Maintenance Engineers
Operations and Process Team Leaders

Course Outlines:

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 a 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

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