In this comprehensive five-day course, participants will be introduced to a systematic approach for diagnosing faults and preventing failures in various types of machinery found in industries such as Oil/Gas, Petrochemical, and other process sectors. The course covers essential strategies for preventive maintenance, offering both an overview and in-depth examination of topics such as metallurgical failure analysis, vibration analysis, and a sequential methodology for troubleshooting and problem-solving in machinery. Through the study of real-world examples, attendees will gain practical insights into effective preventive maintenance practices.

Course Objectives:

Upon the successful completion of this course, each participant will gain an understanding of structured, results-oriented root cause failure analysis methods for all types of machine components and entire machinery systems. Participants will also learn how parts fail, why they fail in a given mode and how to prevent failures. Participants will acquire a thorough understanding of making the best possible use of available failure statistics and how these can be used in a conscientiously applied comprehensive program of specifying, purchasing, installing, commissioning and operating machinery. Further, each participant will be able to:-

§ Execute system approach of failure analysis and troubleshooting and identify the causes of machinery failure and their contributing factors which are often overlooked

§ Gain an in-depth knowledge on metallurgical failure analysis methodology as illustrated by failure analysis of bolted joints and shafts

§ Perform machinery component analysis and reliability improvement by recognizing redesigned opportunities, bearings in distress, coupling failure avoidance opportunities and mechanical seal problems

§ Develop an understanding of continuous reliability improvement and the various approaches to optimized lubrication for pumps and electric motors

§ Apply and gain an understanding on vendor selection and reliability review methods through centrifugal pump selection & compressor reliability review examples and perform troubleshooting of pumps and centrifugal compressors

Who Should Attend?

Engineering and Technical Professionals and Supervisors from any industry
Maintenance Planners and Coordinators
Operations and Manufacturing Professionals and Supervisors
Foremen and Team leaders
Plant Engineers and Maintenance System Professionals
Section Engineers and Planners

Course Outlines:

Strategic Maintenance Issues & Latest Research

Introduction to World Class Manufacturing
The SQC Planning Model
The Strategic Role of the maintenance discipline in the context of organizational excellence and continuous improvement
Maintenance Problems and Objectives (Individual Exercise)
The QMS Maintenance Complexity Model
The Six Schools of modern Maintenance Science
The World Class Maintenance Process (Group Exercise)
Maintenance Maturity Indexing
The Maintenance Cost Ratio

Sustainable Maintenance Performance Improvement

The MVA Model (incl. Group Coding Exercises; Experience; Pay-for-Performance ;)
Cross Referencing Maintenance Objectives (Group Exercise)
'Your Maintenance Costs are too high!'
Classification of Maintenance Work
Reverse Risk Analysis (DDC + Force Field Analysis + CPA)

Sustainable Maintenance Performance Improvement 2

Data / Knowledge Base
Accuracy and Availability of Data / Cost relationship
The Four critical stages of Data Maturity
Logical Critical Thinking vs. Creative Lateral Divergent Thinking
24 Thinking Types
Maintenance Strategy Development and Implementation
Standard Pitfalls for Maintenance Improvement Initiatives
The HR Stratification Model for Multi-Skilling
Nine Generic Problem Solving Techniques
Other Problem Solving Techniques
The QMS Root Cause Failure Analysis Methodology
Case Study: Bell helicopter main bearing failure
Case Study: Broken chain links

Root Cause Analysis

RCFA (Problem Solving)

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