Programs

Course Objective

This course provides a detailed look at Asset Management and influencing factors as well as presents a practical approach to improving reliability in industry. It illustrates in depth the concept, techniques, examples and application case studies.

Course objective is to provide information and practical training that enables attendees and plant level management to successfully select and implement effective maintenance and asset management approaches towards a goal of improved reliability and profitability.

This training is a comprehensive program which can help to support the implementation and management of asset management and maintenance procedures. It trains attendees about the available methods and techniques that can be used to effectively influence organizations outcomes and deliver competitive advantage. It helps in providing the right answers in questions such as: which asset management strategy is suitable in your case, how you can effectively implement it, how you will be able to measure and analyze the implementation results etc.

Upon completion of this course, attendee should fully understand the concept and techniques of contemporary maintenance and asset management and be able to participate, use and apply by himself various techniques, tools and methodologies of maintenance engineering and asset management. It enables attendees to be in a better position to make a sound decision on the usefulness of certain asset management tools for your own working environment.

It is a comprehensive active learning consists of lectures, examples, case studies and practice cases.

Who should attend?

Plant management and supervision personnel responsible for plant maintenance performance improvement includes plant engineering, planning and scheduling and reliability personnel.

Course Duration   

5 days – 30 Hours

Course Contents

Day 1:

Understanding Maintenance and Asset Management

• Maintenance Engineering Fundamentals Review.
• Maintenance and Asset Management Evolution.
• Introduction and Proactive Concept.
• Definitions of Reliability based on industry and application.
• Disadvantages of unhealthy equipment and why to get proactive
• Failure definitions and nomenclature
• Contemporary Asset Management and Maintenance Engineering
• Maintenance and HSE.
• (Practice Case 1: Maintenance and Proactive culture case)

Main Asset Management Blocks and Processes:

• Asset Life Cycle related activities and Costing
• Maintenance & maintenance cycle
• Bath-Tub Curve and Failure patterns.
• P-F Curve as a base for maintenance
• Maintenance Planning & Scheduling
• Reliability within the traditional maintenance models
• Implementation of reliability—key steps towards positive change

(Practice Case 2: Drawing and using P-F curve case)

Day 2:

Maintenance & Asset Management standards, new trends and technologies.

• Asset Management Standard ISO 55001.
  • Introduction, Frame and Requirements
  • Asset Management Policy
  • Strategic Asset Management Plan (SAMP)
• Leadership for Maintenance and Asset Management.
• Value driven Maintenance and Asset Management (Maintenance as Economical added value).
• Use of Big Data and Internet of Things (Iot)

(Practice Case 3: Formulating Asset Management Mission, Vision and Policy)

Asset Management Strategies and Techniques

• Elements of asset management tasks and programs.
• Preventive Maintenance
  • Establishing a Preventive Maintenance Program.
  • Elements of Preventive Maintenance Procedure.
  • Preventive Maintenance Considerations.
• Condition Based Maintenance: Concept, Techniques & Application
  • Establishing an effective Condition Based (Predictive) Maintenance Program
  • Vibration Analysis
  • Thermography inspection
  • Ultrasound inspection
  • Oil Analysis

(Practice Case 4: Selecting Maintenance/Inspection Tasks)

Day 3:

Planning and Scheduling Concepts and Principles:

• Defining planning and scheduling
• Why planning & scheduling
• Planning and Scheduling in Maintenance organization
• Planning organization functions roles and responsibilities
• Maintenance Planning Principles
• Maintenance Scheduling Principles

(Practice Case 5: Developing business case for planning & scheduling)

Maintenance work order requirements, workflow and cycle

• Work order as a maintenance management and control tool.
• Proactive work order cycle.
• Work order system requirements ,elements and contents
• Roles and responsibilities in work order cycles.
• ISO 14224 usage in work orders

(Practice Case 6-: Selecting work order codes and details from ISO 14224)

Maintenance Work Identification and Prioritization

• Early work identification and proactive domains
• Establishing work identification processes and sources
• Identified work types and contemporary distribution
• Major Maintenance Work Identification Issues
• Using work prioritization to effectively manage work resources
• Establishing effective work prioritization system

(Practice Case 7-: prioritizing and assessing work priority)

Day 4:

Maintenance Planning Details and Processes

• Maintenance planner job description and daily activities
• Maintenance planning elements and contents
• Levels of details & how much planning is enough
• Planning sequence step by step

(Practice Case 8-: Developing Job Plan Package)

Maintenance Scheduling Details and Processes

• Maintenance scheduler job description and daily activities
• Maintenance scheduling elements and details
• Work Scheduling Considerations
• Scheduling Success factors
• Scheduling sequence step by step

(Practice Case 9-: Developing Job schedule )

Managing early life cycle phases and capital Projects

• Setting asset management requirements in early life cycle phases
• Managing capital projects and CAPEX requirements

Planning and Managing  Inventories and MRO Spare Parts 

• MRO / Inventory Related Terms & Concepts
• MRO & Inventory System
• Planning for inventory and spare parts management
• MRO & Inventory System ABC Classification
• MRO & Inventory Reorder
• Economic Order Quantity (EOQ)
• MRO & Inventory optimization techniques

(Practice Case 10-: Planning for Spare Part Reorder and EOQ)

Day 5:

Optimizing and Improving Maintenance and Asset Management

• Precision maintenance techniques.
• Computerized Maintenance Management System (CMMS) & EAM.
• Operator Driven Reliability (ODR) and Total Productive Maintenance (TPM).
• Reliability Centered Maintenance.
• Root Cause Failure Analysis.
• Lean Maintenance Management.
• Maintenance Planning & Six Sigma Improvement Projects.
• (Practice Case 12-: Building Maintenance Strategy with RCM)

Maintenance and Asset Management Organization  

• Maintenance Organization types and roles.
• Process approach and strategic layouts.
• Customer approach and SIPOC methodology
• Organizational horizontal and vertical alignment.
• Human Capital Management and workforce management.
• Maintenance outsourcing management.
• (Practice Case 13-: Building Maintenance Organization with SIPOC Approach)

Measuring Performance and KPIs

• Why we need to measure
• Measuring maintenance and asset management
• Leading and lagging KPIs
• Developing and selecting representing KPIs
• Measuring Planning and Scheduling performance