The implementation of efficient Planned & Predictive Maintenance practices is crucial for the success of any company and forms an essential component of maintenance management strategies like RCM, RBM, TPM, and even 6-Sigma. This comprehensive 5-day program is specifically designed to provide valuable insights to both newly qualified professionals and experienced practitioners involved in the establishment or audit of a comprehensive Maintenance system. The program encompasses all the necessary steps involved in developing a successful Planning & Predictive Maintenance program, starting from system development and concluding with the establishment and operation of a well-managed Maintenance system.

Course Objectives:

Leading industrial organizations are evolving away from reactive (“fix-it-when-it-breaks”) management into predictive, productive management (“anticipating, planning, and fix-it-before-it-breaks”). This evolution requires well-planned and executed actions on several fronts.

Who Should Attend?

Course Outlines:

The Need for Maintenance

Failure Mode Effect & Criticality Analysis (FMECA)

Causes of Failures
Likelihood & Severity of Failure – Risk Analysis
Reliability Centered 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

Developing the CMMS

Database Construction

Installed Asset Base
Hierarchical Structure
Procedures and Plans

Resources

Dedicated Manpower
Contractors
Specialist Tools

Maintenance Strategies

Centralized/Decentralized
Life/Emergency/Corrective/Planned
Planned & Predictive

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

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

Control of the Maintenance Process

CMMS Integration

Predictive Maintenance Interface
Optimizing 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

Filters