Effective Plant Maintenance Management

This two-day course is for maintenance personnel, operators and managers who desire to understand how plant maintenance can increase the efficiency of their maintenance program while reducing costs. This course will teach you what equipment to monitor, what technologies to monitor it with and how to measure your success. 

Participants will gain an understanding of real-world applications to help them implement a maintenance program at their facility. With ever-increasing demands from top management to do more work and decrease costs, investing in maintenance makes more sense today than ever. While many organizations still rely heavily on time-based maintenance, it is a proven fact that maintenance requires personnel who reduce costs and downtime.

This course provides the fundamentals of maintenance applicable to plants and facilities. Maintenance will provide engineers with a framework to make the right decisions on what equipment needs repair, replacement, refurbishment etc., what technologies to use to meet their needs and how to measure the effectiveness of their decisions. In addition to exposing participants to the principles and options of a program, they will learn about real-world applications.

By the end of the course, participants will be able to go back to their facility and immediately apply what they learned to help make their maintenance process more efficient and less expensive.

This course is industry designed, to provide a broad understanding of the improvement methodology, concepts, and process. The methodology is presented with case studies and examples drawn from services, business processes and applications. With a heavy practice orientation, much of your time will be spent working through interactive practical exercises assessments and attending site visits.

This training program is designed to provide an understanding of engineering-related problems related to the industry globally and a clear sense of what is required to effectively structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem-solving initiative within their organization.

On successful completion of this course, the participant should be able to:

• Understand the benefits and implications of effective equipment maintenance management, engineering problem-solving programs and relate the concepts to the overall business mission and objectives.
• Think about his/her organization as a collection of processes, with inputs that determine the output.
• Use the concept of effective equipment maintenance management engineering problem-solving to evaluate the capability of a process or organization.
• Recognize the engineering problem-solving model used to improve processes.
• Recognize the organizational factors that are necessary groundwork for a successful engineering problem-solving program.
• Integrate the process equipment and effective equipment maintenance management engineering problem-solving program effort with other process improvement initiatives.

Training methodology

• The latest educational methods and strategies will be utilized.
• The course is designed to maximize delegate participation.
• Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
• The course shall be conducted through lectures, case studies, group discussions, exercises and site visits to reinforce participant’s learning.

Course format

• The course consists of formal content presentation interspersed with content quiz sessions. The presenter’s style involves intensive participant participation.

Who should attend

• Technicians, Chargemen, Wiremen, Maintenance and Facility Managers, Property Managers etc.

Day 1

• Introduction to Maintenance Management
• Definition of Maintenance
• Maintenance Objectives
• Primary Goals
• Secondary Goals
• Management and Structure of the Maintenance Function
• Planning
• Scheduling
• Total Productive Maintenance (TPM)
• Definition
• Operator Responsibility
• Obstacles to Achieving Full Equipment Effectiveness
• Types of Maintenance Activities
• Reactive or Corrective Maintenance
• Preventive Maintenance (PM)
• Predictive Maintenance (PDM)
• Maintenance Department Organization
• Centralized Maintenance Department
• Decentralized Maintenance Organizations
• Combined Systems
• Maintenance in Service Industries
• Changing Maintenance Strategies
• Preventive Maintenance (PM)
• Introduction
• Routine Preventive Maintenance
• Major Preventive Maintenance
• Equipment History
• Establishing and Updating History
• Determining Reliability, mean time between failure (MTBF) and Availability
• Establishing a System of Criticality
• Three Degrees of Equipment Criticality
• Planning for Preventive Maintenance
• Design for Maintainability
• Cost of Preventive Maintenance

Predictive maintenance

• Introduction
• Definition of Predictive Maintenance (PDM)
• PDM’s Reliance on Science and Technology
• Decision Factors Regarding PDM
• PDM’s Quantitative Nature
• Approaches to Data Collection
• Data Analysis
• Predictive Maintenance Techniques
• Vibration Analysis
• Chemical Analysis
• Tribology
• Thermography
• Ultrasound Techniques

Site Visit-part A

• This site visit will encompass the air-conditioning plant room, fire protection services plant rooms and the domestic cold water plant rooms etc.

The objectives of this site visit are to observe and comment on current practices of:

• Corrective maintenance;
• Preventive maintenance;
• Housekeeping;
• Record keeping;
• Teamwork;
• Problems encountered by the maintenance personnel;
• Recommendations and follow-up of future improvement works etc.

Day 2
Implementing Total Productive Maintenance (tpm)

• Introduction to TPM
• Successful Implementation of TPM
• A Change in the Corporate Culture
• Deming’s Legacy
• Change Management and TPM
• The TPM Journey
• Introducing and Promoting TPM
• Communicating the Goals and Objectives of TPM
• Assessing Current Conditions
• Assessing Current Maintenance Effectiveness
• Overall Equipment Effectiveness (OEE)
• Availability
• Efficiency
• Quality
• TPM Activities and Processes
• Cleaning
• Developing Lubrication Standards
• Inspection
• Workstation Organization
• Continuous Process Improvement

Tpm implementation and process improvement tools

• Introduction
• Benchmarking
• A Blueprint for Benchmarking
• The Five Pillars of TPM
• TPM Principles
• The Eight Pillars of Maintenance
• Failure Mode and Effect Analysis (FMEA)
• FMEA Categories

Facility Maintenance Projects

• Definition of a Maintenance Project
• Successful Project Management
• The Role of the Project Manager
• The Project Manager’s Responsibilities
• Maintenance Operations Analysis
• Maintenance Operations Procedures
• Regular Maintenance Tasks Identified
• Implementing Specific Maintenance Activities
• Scheduling Work Items
• Time Estimates
• High-Level Estimates
• Project Management Tools and Techniques
• Basics of the CPM and PERT Networks
• PERT Network Probability Analysis
• CPM/ Crash Analysis: An Illustration
• A Realistic (Complex) PERT Project Example
• Computer Program Solutions
• Activity-on-Node Network Diagram Convention
• More Computer Printout Examples
• Manual Forward / Backward Pass Procedures on Activity-on-Node Diagrams