Maintenance Training Courses

The following five maintenance
training courses are designed to prepare engineers/managers to deal more effectively
with one of the challenging and demanding tasks of enterprise activities. Top of the
notch maintenance practices are inherent in almost every venture and have far
greater impact on enterprise competitiveness and success than do other activities .
Currently , 5 courses are offered, exact date and location will be posted in due
time. Any of the courses can be offered in-house for a limited
group by special arrangement with the customer,



1. BEST
PRACTICES IN MAINTENANCE : TPM or RCM

2.
APPLIED RELIABILITY CENTERED MAINTENANCE (RCM) AND

HAZARD
AND OPERABILITY STUDIES (HAZOP)


3.
MAINTENANCE MANAGEMENT : BEYOND THE TECHNIQUES


4. COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEMS (CMMS)



5. MAINTENANCE, REPAIR AND OPERATION MRO OF THE PROCESS PLANT

During the last few years
there has been a gradual attitude change in how general corporate managers view the
maintenance
function.
One of the most important
factors forcing this change was that maintenance departments became major cost
centers within
those organizations.
Through the application of Good Management Practices and with the use of sound
technical
expertise, maintenance
department, will produce dividends in the immediate, as well as for the long term
value enhancement.
A successful prescription
is a mix of Total productive maintenance (TPM) and Reliability-Centered Maintenance
(RCM).
Total productive
maintenance (TPM) is the systematic execution of maintenance by all employees
through small group activities.
The dual goals of TPM are
zero breakdowns and zero defects. Reliability-Centered Maintenance (RCM) is a
systematic approach
for defining
maintenance tasks for engineered systems. It has been successfully applied in
several industries, most notably
in the chemical,
petroleum, manufacturing, aviation, and electric utility industries. It enforces
organizations to systematically
evaluate maintenance
needs based on an understanding of system function and the types of equipment
failures that can cause
losses of system
functions


Participants Profile

Senior and middle level Maintenance
Managers, Operations Managers, Plant Managers and Engineers, senior and middle level
Production Managers and Technical Managers who are going to be responsible for
directing the application of RCM/TPM or for auditing its results.


Methods of Instruction

This course provides an
introduction to the principles, method of application and tools used in each of the
two strategies. It
includes cases that allow
participants opportunity to provide first-hand understanding of the steps an analyst
would perform and provide maximum involvement by participants. Practicality and
results are stressed . Situations in manufacturing and service organizations
are used along with decision exercises, videos and computer applications.


Tool kit



• 
  
  Modern Maintenance Strategies (Overview of Maintenance Strategies, RCM and
  TPM. Back to the basics)
  
  
• 
  
  Basics of TPM (Main differences between "traditional" TPM. Overall
  Equipment Effectiveness (OEE) and Overall Craft Effectiveness (OCE). The 6 Big
  Losses associated with Plant and Equipment. The visual factory.
  
  
• 
  
  Losses, Productivity and Quality (Classification of Losses related to
  Equipment. Losses due to set-ups, start-up, changeover and machines idling. The
  TPM approach to zero breakdowns. Poor productivity and reduced machine
  speed/capacity. Eliminating poor quality. Zero-defects methods. Waste of manpower
  next to Machines and Equipment
  
  
• 
  
  Reliability & Maintainability (RCM analysis and the decision process,
  Simple Reliability, Reliability & Maintainability and How to use reliability
  information for maintenance)
  
  
• 
  
  Performing RCM (System selection - criticality analysis. FMEA - failure modes
  and effects analysis. System function and functional failures. Failure modes,
  effects and FMECA. Root Cause Problem Elimination)
  
  

Reliability Centered Maintenance is an approach to maintenance that combines
different maintenance practices and strategies to maximize the life that a piece of
equipment functions in the required manner at minimal cost. RCM strives to create
the optimal mix of an intuitive approach and statistical analysis to decide on how
to maintain facility equipment.
HAZOP (Hazard and Operability Study) is a structured method for identifying hazards
and problems associated with the operation of a plant. In principle, both
operability and reliability considerations have been a part of the HAZOP
methodology. The results of a HAZOP study allow engineers to improve the safety of
an operation and to highlight operability problems starting at an early stage in
project development to existing plants which have been operating for many years.

In modern industries, a common, in-depth knowledge of both tools is a must for a
smooth and sound communication among operation and maintenance staff and Hazop team,
which contribute to the introduction and application of either tool, increase
efficiency, improve the quality of both activities and eliminate duplication of
effort by different groups in the same organization .


Participants Profile


The course is intended for people in the process industries who participate or
intend to participate in either the application of RCM and/or HAZOP studies. They
include project engineers, senior and middle level maintenance managers and staff,
operations managers, plant managers and engineers, senior and middle level
production managers and technical managers .
The course requires a basic knowledge of mathematics and statistics and it is
assumed that attendees will be familiar with the relevant processing operations. It
is an engineers only course.


Methods of Instruction


This workshop provides an introduction to the principles and tools used in RCM
analysis and Hazop studies with a special emphasis on the applications. It includes
cases that give participants opportunity to gain a hands-on experience of the steps
an analyst would perform and provide maximum involvement by participants. Situations
in process industries, manufacturing and service organizations (according to the
actual orientation of participants) are used along with videos and computer
applications. People attending the course will be grouped into syndicates of
three or four and each group asked to solve a particular Case Study.


Tool Kit

• Overview of world-class maintenance programs. A review of basic statistics.
  
• RCM introduction. The failure process. The bathtub curve.
  
• Types and causes of failure. Criticality analysis. FMEA and FMECA.
  
• Reliability, availability and maintainability - basic indicators
  
• R C M analysis software
  
• Hazop introduction. Hazard Identification and hazard in the work environment
  
• Checklist Analysis. What-if Analysis. What-if/Checklist Analysis.
  Identification and Selection of Optimum Barriers. The Hazard-Barrier. Matrix
  Barrier.
  
• Reliability Risk-based Approach to Hazard and Barrier Analysis. Hazard and
  Operability Study. Fault Tree Analysis (FTA)
  
• Reporting the Process Hazard Analysis. Review of the Process Hazard
  Analysis
  
• Hazop software
  

This course is designed to prepare maintenance engineers/managers to deal more
effectively with the difficult and demanding tasks of managing maintenance,
maintenance planning and maintenance control. Such problems are inherent
in almost every enterprise and have far greater influence on enterprise success than
do other activities .
To know how to obtain clear, usable knowledge of what are modern analysis tools
and what they will value to your business and to discover how to reengineer the
maintenance system from a service department to a productive entity


Participants profile


The program is designed for mid- to top level maintenance managers from any
functional area who want to broaden and improve their technical and managerial
skills. It is appropriate for both the experienced engineer and the individual being
developed for a mid-level position. There are no formal educational requirements for
admission, but participants should have an understanding and appreciation of basic
maintenance concepts as well as some previous managerial experience


Methods of Instruction


The emphasis is on interactive learning. Lectures are combined with case studies,
small group exercises, and computer simulations. Question/answer methods are
coupled with interactive methods to provide the maximum exchange of information.



Tool Kit

• Analysis of maintenance activities and development of the maintenance plan
  
• Scheduling and control of maintenance activities
  
• Management of maintenance team
  
• Modeling of maintenance policy ( Preventive maintenance - Predictive
  maintenance - Proactive maintenance)
  
• Elements of reliability centered maintenance RCM (Statistical background
  - Failure analysis and implications - Computer applications)
  
• Spare parts and maintenance materials inventories
  
• Maintenance cost control
  
• Computerized maintenance management CMMS
  

Computerized Maintenance Management Systems (CMMS) provide a way for companies to
track equipment and inventory assets, detail when and how work orders are to be
performed in maintaining those assets, and accumulate all of the associated costs
for labor, materials and tools. Most large corporations cannot remain
competitive without an effective automated maintenance system..


Participants Profile


This course is targeted for all companies interested in Computerized Maintenance
Management Systems, where advanced techniques will assist in a successful
implementation and sustaining use of CMMS. Recommended attendees should include
Plant Managers, Maintenance Engineers, Maintenance Managers, Maintenance Planning
and Scheduling Engineers, Maintenance Team Leaders, Purchasing Managers and Stock
Room Supervisors and Technical Managers who are going to be responsible for
directing or conducting an integrated CMMS approach


Methods of Instruction


This workshop provides an introduction to the principles and tools used in CMMS
analysis with a special emphasis on the applications. It includes cases that give
participants opportunity to gain a hands-on experience of the steps a system analyst
would perform and provide maximum involvement by participants. Situations in
manufacturing and service organizations are used alongwith videos cases

Those people attending the course will be grouped into syndicates of three or four
and each group asked to solve a particular real life problem. During the course,
attendees will have the opportunity to review an “On-line Computer Maintenance
Management System” and bring along their laptop computers to join in an interactive
session.


Tool Kit

Overview of world-class maintenance practices.

The basic Maintenance Department’s function and objectives. A CMMS
overview of Functions and Benefits. Deploying a Computerized Maintenance
Management System. Define the Scope of the System, Applications and Functions.

Defining Facilities Maintenance Management Process. Managing Assets/Equipment.
Managing Parts Stores.

Key steps in developing a Preventive Maintenance Program. CMMS basic modules.
System Requirements and Responsibilities. Database Set-up. Maintenance Flow
Chart. Purchasing and Receiving Flow Chart.

Maintenance Management System Functions. Service Calls – Work Order Request.
Work Order Process: Object and Goals. Planning and Scheduling

Preventative Maintenance - Task & Scheduling. Parts Material –
Availability. Inventory Management. Purchasing. Procurement.
Maintenance Management Process. Management Data Analysis

CMMS Applications. Rolling Stock versus Fixed Assets. Bar Coding
Systems. Hand held collection devices. Work Environment and Cultural Change.

CMMS and predictuve maintenance technologies.

Petroleum (oil and gas), petro-chemical and chemical process industries provide
the building blocks for many products. Process industries, characterized by high
investments and use of advanced technology, play a major role in economy and
contribute a high percentage of the total GDP in many countries. These industries
face major challenges to meet the needs for high competitiveness within a global
economy.
The aim of this short course is to examine the key issues and techniques required
for a plant engineer to operate successfully in the process industries sector.



Participants profile


The program is designed for mid-to top level plant and maintenance
engineers/managers who want to broaden and improve their technical and managerial
skills. It is appropriate for both the experienced engineer and the individual being
developed for a mid-level position. There are no formal educational requirements for
admission, but participants should have an understanding and appreciation of basic
maintenance and operation concepts as well as some previous managerial experience.



Methods of Instruction


The emphasis is on interactive learning. Lectures are combined with case
studies, small group exercises, and computer simulations. Question/answer
methods coupled with interactive methods and role playing management games provide
the maximum exchange of information.


Tool Kit

• Issues of plant construction, start-up and commissioning. Contract
  terms and monitoring.
  
• Process management : planning and control of plant operation and maintenance
  
• Spare parts procurement and control. Key performance indicators KPI
  
• Reliability centred maintenance RCM
  
• Computerized maintenance management systems CMMS
  
• Analysis of financial and technical productivity and assessment of the
  process plant metrics