Excellence in Maintenance and Reliability Management: Preventive and Predictive Maintenance and Machinery Failure Analysis

Introduction

Achieving excellence in maintenance and reliability is the aim of every organization that depends on its physical assets to achieve business objectives. Lower profit margins have made reducing maintenance costs imperative to the survival of many organizations. The overall cost of asset ownership is closely tied to the outcomes of reliability, durability, and longevity of physical assets. This training course is about developing and implementing the strategy and tactics that deliver the outcomes we need.

This Excellence in Maintenance and Reliability Management training course starts with the key aspects that lay the foundations and cornerstones of an effective maintenance function. It introduces reliability strategies such as FMECA, TPM, RCM and RCFA to highlight their costs and benefits. The Excellence in Maintenance and Reliability Management training course will then demonstrate how these strategies are used to derive the different maintenance tactics of predictive, preventive, detective and repair-after-failure maintenance tactics.

An in-depth analysis of risk-based processes such as Reliability-Centered Maintenance, the principles of Risked Based Maintenance and Totally Productive Maintenance; as well as a unique, practical application of the methodologies to demonstrate how they can be applied in the real world; are integral components of this training course.

Participants will develop the following competencies:

• Asset Functional Analysis
• Failure of Forecasting Risk Assessment
• Maintenance Strategy and Tactics Development
• Root Cause of Failure Analysis
• Reliability Improvement Project Facilitation

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

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice and the fundamentals of shutdown and turnaround management. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

Personnel who should attend are:

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

Course Outline

Day 1: 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

Day 2: 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

Day 3: 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

Day 4: 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

Day 5: 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