Optimizing Equipment Maintenance and Replacement Decisions

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Optimizing Equipment Maintenance and Replacement Decisions Course
Introduction:
Prominent companies in the process and petrochemical industry have formulated their maintenance practices by focusing on optimizing predictive maintenance management systems. This approach proves effective for both stationary and rotating equipment and encompasses continuous condition monitoring, as well as detailed inspections of critical equipment elements. The optimization of maintenance activities includes efficient spare parts handling, selecting appropriately sized maintenance crews with the required skills, and considering potential outsourcing or subcontracting options.
Course Objectives:
By the end of this training course, the participants will be able to:
· Identify equipment failures and the impact on plant reliability
· Understand the cost-effectiveness of Preventive / Predictive Maintenance program
· Apply techniques of optimization of various maintenance activities
· Define criteria for work-crew size, spare parts and equipment replacement
· Make the important decision on the basis of the cost and benefit analysis
· Incorporate safety objectives to the equipment repair or replacement optimization
Who Should Attend?
Personnel who should attend are:
- The operation, Technical Production & Service Professionals
- Technical Professionals responsible for maintenance and repair of equipment
- Professionals involved in inspection and reliability
- Technical Professionals dealing with risk assessment and integrity analysis
- Technicians dealing with regulating and metering and other measurements
Course Outlines:
Physical Asset Management & Failure Analysis
- Physical Asset Management
- Maintenance Management: Preventive / Predictive Approach
- Nature and Modes of Equipment Failure
- Failure Modes & Effect Analysis (FMEA)
- Analysis of Component Failure data using the Weibull Distribution
- Censored Data, the 3-Parameter Weibull, and the Kolmogorov-Smirnov Test
Preventive Maintenance & Spare Parts Replacements
- Reliability and Availability Concept: MTBF & MTTR
- Reliability Improvement through Reduction of Downtime
- Maintenance Performance Quantification
- Preventive Maintenance & Spare Part Handling
- Spare Parts Provisioning: Prediction Models and Techniques
- Management of Change: In-Kind Spare Parts
Equipment Inspection & Fitness for Service
- Condition Monitoring & Inspection
- Risk-Based Inspection (RBI)
- Risk Matrix: Management and Mitigation Measures
- Reliability Improvement through Inspection
- Inspection Scope & Frequency
- Fitness For Service Analysis (FFS)
Economics of Maintenance, Repair & Replacement
- Management of Maintenance Resources
- Effective Use of CMMS
- Maintenance Organization Analysis: Crew size
- Equipment Repair or Replacement Decision
- Economic Aspect of Maintenance Outsourcing: Subcontract
- Economic Aspect of Equipment Replacement
Total Productive Maintenance & Safety
- Capital Investment in Equipment and Maintenance: ROI
- Total Productive Maintenance
- Safety in Maintenance Work
- KPI and OEE: Leading and Lagging Indicators