Fundamentals of Best Practices in Maintenance

Fundamentals of Best Practices in Maintenance

Course Objectives:

At the end of the course, participants will be able to:

• Understand the asset (equipment) life cycle and the role of maintenance in extending asset life.
• Understand different types of maintenance, such as preventive maintenance, predictive maintenance, reliability-centered maintenance (RCM), and root cause failure analysis (RCFA).
• Explain how to select the most cost-effective maintenance strategy for each asset to reduce failures, risks, and costs.
• Efficiently use Computerized Maintenance Management System (CMMS) to implement a successful maintenance management program.
• Apply key performance indicators (KPIs) for assets and maintenance and compare them with leading global benchmarks.

Target Audience:

This training course targets relatively new professionals in the field of maintenance management, including maintenance engineers, maintenance technicians, maintenance supervisors, maintenance managers, operators, operational supervisors, process engineers, and technicians.

Program Content:

• Maintenance industry concepts
• Definition of maintenance
• Definition of maintenance management and reliability
• Importance and objectives of maintenance
• Relationship between maintenance and reliability
• Types of maintenance tasks
• Maintenance, repair, and overhaul (MRO)
• Definition of assets

Maintenance Applications:

• Facility and building maintenance
• Facility maintenance vs. industrial maintenance vs. property maintenance
• Equipment maintenance
• Industries that use equipment maintenance
• Fleet maintenance
• Organizations that use fleet maintenance

Major Types and Strategies of Maintenance (Part 1):

• Definition of reactive maintenance
• Workflow of reactive maintenance
• Types of reactive maintenance
• Run-to-failure (RTF) maintenance
• Workflow of run-to-failure (RTF) maintenance
• Knowing when to use run-to-failure (RTF) maintenance
• Benefits of run-to-failure (RTF) maintenance
• Advantages and disadvantages of reactive maintenance
• Definition and implementation of corrective maintenance
• Essential requirements for effective preventive maintenance (PM)
• Workflow of preventive maintenance
• Types of preventive maintenance
• Benefits of preventive maintenance

Planned and Scheduled Maintenance:

• Workflow of planned maintenance
• Benefits of planned maintenance
• Workflow of scheduled maintenance
• Benefits of scheduled maintenance
• Scheduled maintenance vs. deferred maintenance

Major Types and Strategies of Maintenance (Part 2):

• Predictive maintenance (PdM)
• Definition of predictive maintenance
• Workflow of predictive maintenance
• Implementation of predictive maintenance
• Types of predictive maintenance
• Condition-based maintenance
• Vibration analysis – standards
• Acoustic analysis (ultrasonic) – standards
• Infrared analysis – standards
• Oil analysis – standards
• Return on investment (ROI) for predictive maintenance
• Difference between preventive and predictive maintenance

Fundamentals and Tools for Selecting the Right Maintenance Strategy:

• Critical assets
• Legal requirements
• Work planning
• Frequency (number of times)
• Budget
• Communication
• Reliability-centered maintenance (RCM)
• Definition of reliability-centered maintenance (RCM)
• Workflow of reliability-centered maintenance (RCM)
• Evaluation criteria for reliability-centered maintenance (RCM)
• Components of reliability-centered maintenance (RCM) program
• Reliability-centered maintenance (RCM) vs. preventive maintenance

Objectives and Challenges of Maintenance:

• Optimal availability
• Optimal operating conditions
• Maximizing maintenance resources
• Optimal equipment life
• Minimum spare parts inventory
• Quick response capability
• Maintenance policy and strategy
• Maintenance management process

Failure Analysis:

• Root cause analysis (RCA)
• 5 Whys
• Fault tree analysis
• Fishbone diagram
• Implementing root cause analysis (RCA)
• Failure codes and types
• Types of failures and their effects analysis (FMEA)
• Effects of failures

Maintenance Techniques: Computerized Maintenance