Advanced Maintenance Management

Advanced Maintenance Management

 

Date & Location: (2-6/April) Kuala Lumpur – ( 19-23/Nov) Istanbul

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Course Overview

Introduction:

Delegates will learn and review the core competencies required for successful operation and implementation of an effective operations process in the current global economic downturn. They will complete an in-course assignment, which analyse their own process operation and which will serve as an action plan for improvement.

 

Program Objectives:

Participants attending the course will:

  • Demonstrate the latest concepts and techniques required for managing or supervising a maintenance unit
  • Examine the organizational and managerial considerations for effective maintenance work
  • Apply techniques to measure Overall Equipment Effectiveness (OEE)
  • Distinguish and optimize the special characteristics of maintenance activities
  • Debunk safety myths safety and identify unsafe acts and conditions
  • Identify common maintenance Key Performance Indicators (KPIs) and develop the maintenance department scorecard

 

Who Should Attend?

Those involved in the supervision or management of maintenance activities; also anyone interested in learning more about the critical role of maintenance in a company.

 

 

Program Outline:

DAY 1

Introduction to advanced maintenance management

  • Objectives of maintenance management
  • Asset management
  • Maintenance life cycle
  • Common maintenance management problems
  • Typical responsibilities of a maintenance manager
  • The maintenance organization

DAY 2

Continuous improve practices in maintenance

  • 5S Model to improve productivity and reliability
  • Defining 5S and its principles
  • Relationship between maintenance and production
  • Determine needs and requirements
  • Applying the principles of 5S to continuous improvement

DAY 3

Management of maintenance

  • Maintenance strategies
  • Overall Equipment Effectiveness (OEE)
  • OEE calculations
  • Equipment failures and patters
  • Failure modes and effect analysis
  • Emergency and preventive maintenance
  • Common preventive maintenance tasks
  • Predictive maintenance
  • Computerized Maintenance Management Systems (CMMS)
  • Typical CMMS modules

DAY 4

Maintenance planning and control

  • Maintenance work flow process
  • Work requests and work orders
  • Work planning and scheduling
  • Backlog management
  • Resource management
  • Spare parts management
  • Maintenance master budget
  • Capital budgeting
  • Maintenance initiatives
  • Replacement analysis of assets
  • Maintenance operating budget
  • Innovation and creativity

DAY 5

Safety in maintenance

  • Myths about safety
  • Why the concern for safety
  • Unsafe acts and unsafe conditions
  • Safety culture elements
  • Conducting safety audits

 

Program Objectives:

Participants attending the course will:

  • Gain a broad understanding and appreciation of the core functional aspects of how an effective operational process should operate
  • Review the five standard maintenance improve tactics and their selection technique to ensure reliable process plant & equipment
  • Learn how to develop a comprehensive operational process resource and support system analysis
  • Understand the principles of PAS 55, the most recent maintenance process audit standard
  • Gain insight and understanding into the unique leadership and motivation principles required for technical management

 

Who Should Attend?

  • Engineering and Technical Managers and Supervisors from any industry
  • Maintenance Planners and Coordinators
  • Operations and Manufacturing Managers and Supervisors
  • Foremen and Team Leaders
  • Plant Engineers and Process System Managers
  • Section Engineers and Planners

 

 

 

Program Outline:

DAY 1

Review of Basic Modern Operations Practice

  • Review of modern operational practice in the light of the global economic recession
  • Integration of maintenance and production to establish a world class operations department
  • Generic performance measurement model using a 6 point scale
  • Combining the parameters of speed, quality, and cost in maintenance performance measurement
  • The 10 point planning standard and the role of the planning department
  • Developing effective strategies for the operational process in order to achieve organizational excellence and continuous improvement

DAY 2

Standard Maintenance Improvement Initiatives

  • Selecting the ‘correct’ maintenance tactic mix
  • Reliability Centered Maintenance (RCM)
  • Total Productive Maintenance (TPM)
  • Condition Based Maintenance (CBM)
  • Time Based Maintenance (TBM)
  • Run-To-Failure (RTF)

DAY 3

Operational Resource Analysis

  • A ‘blueprint’ for effective operational practice
  • Resource and support system analysis with ‘Gap Analysis’
  • Leadership development and motivation of operations employees
  • The PAS 55 Maintenance Process Standard
  • Principles of information management
  • Risk identification, assessment and control
  • Training, awareness and competence

DAY 4

Problem Solving in the Operations Environment

  • Theory of inventive problem solving
  • Problem solving techniques and case studies
  • Exercises and facilitation

DAY 5

Scenario Analysis and Action Plan Development

  • Review and analysis of your specific operations environment
  • Assessment assignment and scoring of your operational process