course | Maintenance and Reliability Management

Introduction
 

• Evolving Maintenance through the Industrial Age
• Specific Maintenance Definitions
• Identification of Maintenance type according to response and effect
• Basic Effective Maintenance Management cycle
   

Assessment and continuous improvement through Key Performance Indicators, KPIs
 

• What cannot be measured cannot be controlled
• The development cycle for choosing and using KPIs
• Understanding the important concept of Dashboards
• Designing your maintenance Dashboard
• Essential Maintenance and Reliability KPIs as per SMRP 

Work identification and prioritization: Machine failure and Root Cause Analysis
 

• Why Machine Failure?
• Understanding and identification of Failure Modes
• Understanding the importance and effect of prioritization of work
• Why Root Cause Analysis techniques are building blocks of a successful Maintenance Organization
• Failure Modes and Effects Analysis Methodology – FMEA
• Other RCA tools
• Case Studies
   

Basic tools for Maintenance Program success
 

• Technical report writing – what is not documented is lost!
• The basic concepts of outsourcing a maintenance task
• Basics of Data Analysis and Representation
• Using your data to get information – Data filtering, sorting, and credibility
• Using your information to build knowledge – Knowledge base
• Basics of Statistical analysis in maintenance 

What is your Maintenance Management System?
 

• Principles of Maintenance Management
• Reliability Centered Maintenance, RCM
• Basic concept
• Application
• Total Productive Maintenance, TPM
• Basic concept
• Application
• Visual Management and
• A base for effectiveness, efficiency, and success
• What is Overall Equipment Effectiveness (OEE)?
• Applying Risk Management to assist in work prioritization
• Computerized Maintenance Management System, CMMS
• Basic concepts of CMMS
• Choosing the suitable CMMS for your organization's needs
   

Maintenance Planning
 

• Identifying and Measuring workload and the concepts of resources allocation
• Control Absenteeism, tardiness, and overtime
• Planning Principles.
• The tasks to be implemented
• The tools for performing the tasks
• The working environment
• Authorization of works/tools/accessibility
• Role of Planner
• The characteristics of the person
• The needed skills of the planner
• The inputs and the outputs
• Creating and managing the Maintenance Plan based on multiple time segments (Annual, monthly, weekly, Daily)
• Understanding and using of Work Orders Management System 

Maintenance scheduling
 

• Understanding the difference between Planning and scheduling
• Scheduling Principles
• The tasks to be implemented
• The tools for performing the tasks
• The working environment
• Authorization of works/tools/accessibility
• Scheduling techniques based on specific parameters (urgency, criticality, cost, internal client requirements, resource allocation, etc.)
• Periodic Maintenance Scheduling (Daily – weekly – other)
• Role of Scheduler
• The characteristics of the person
• The needed skills of the planner
• Maintenance schedule compliance
• Effective methodologies of backlog management
   

Continuous improvement in Maintenance Management
 

• Learning from the past to improve the future in Planning and Scheduling
• Losses in a system: The Lean manufacturing methodology
• Inconsistency in performance: The 6 Sigma methodology
• Lean Six Sigma and its application in maintenance and reliability 

Understanding Cost in Maintenance (according to time availability)
 

• Elements of Cost in owning and operating machinery and production lines
• Life Cycle Costing, LCC, and Total Cost of Ownership, TCO
• Managing your spare parts through the effective ABC Stock Analysis process