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Uptime Strategies for Maintenance Excellence

Duration: 2 Days  | 9 am – 3:30 pm
Wednesday – Thursday

22nd – 23rd Septembet 2021

Live Stream + Online Training

(GMT +4 or Gulf Standard time)

COURSE OUTLINE:

The course aims to produce skills to yield a reliable operating environment that maximizes uptime whilst minimizing operational costs. In addition, process safety and asset integrity are not compromised.

This workshop will provide you with the skills necessary to understand the effectiveness of current maintenance practices, Underlining:

  • What areas requiring development
  • What capabilities to execute and a realistic plan for putting all of this in place.
  • What select skills are required to identify opportunities and effectively utilize modern technologies
  • Example: Sensors in conjunction with the Industrial Internet of Things (IIoT).
  • Applying asset management in this manner will contribute to the sustainable operation of a wealth-generating entity.

The course underscores the importance of interactions and cooperation between the three key functions to achieve the optimum reliability level of a plant

  • Engineering
  • Operation
  • Maintenance

It drives home this key issue with practical examples of significant failures that have resulting from a lack of understanding of the roles, responsibilities, and interfaces between these functions.

KEY LEARNING OUTCOMES:

  • Understand operational asset efficiency, its associated risks and how this can help increase availability; achieve production targets while containing cost and exploiting opportunities to decreasing costs.
  • Understand the fundamentals of Reactive Maintenance, Preventive Maintenance (PM), Predictive Maintenance (PdM) and Impact Driven Asset Management (IDAM).
  • Understand the Digital Twin concept and benefit from its application.
  • Learn what the roles, processes, and procedures to ensure organisational effectiveness is, and how they are put into action through Total Productive Maintenance (TPM).
  • Describe the key aspects of improving reliability at the equipment level that can make a significant difference to the in-service time of equipment, the costs related to over and under maintaining and the optimization of asset utilization.
  • Apply an optimized spare-part inventory strategy, preventing spares unavailability by managing critical spares and vendor managed inventory (VMI) agreements.
  • Apply the concepts of reliability-based maintenance within your current maintenance strategy, avoid the pitfalls of reliability improvement-exercise implementation, and ensure the realization of short- and long-term gains.

DAY 1

Session 1: Asset Management: An Overview:

  • Sustainability Principles
  • Impact of Incidents

 Session 2: Managerial Terminology and Approach:

  • Managerial Terms
  • Operational Integrity Management

Session 3: Generation of Wealth:

  • Wealth Producing Enterprise
  • Plant Performance and Machine Lifecycles

Session 4: Asset Management: Financials:  

  • Time Value of Money
  • Estimating and Budgeting
  • Life Cycle Cost (LCC)
  • Concept of Value in Asset Management

Exercise: Contribution of Maintenance to the Value Chain.

Session 5: Organizational Aspects of Reliability:  

  • Functions and Roles
  • Execution and Supervision
  • Training and Succession Planning

Session 6: Risk Management and Asset Management

  • Fundamentals of Risk and Probability
  • Risk Groups and Task Prioritization
  • Hazards and Risks

Session 7: Operational Integrity and Asset Management:

  • The Starting Blocks
  • Management of Data

Session 8: Sustainability: Technical Foundation:

  • Peak Performance
  • Process and System Health

Session 9: Changing the Status Quo:

  • Failure Mode and Effects Analysis (FMEA)
  • Root Cause Analysis Principles (RCA/RCFA)
  • Fault Tree, Event Tree Analysis and Bowties
  • Reliability Centered Maintenance (RCM)

DAY 2

Session 10: Leveraging the Computerized Maintenance Management System (CMMS):

  • Work Orders and Resource Management Optimization
  • Critical Spares Management Optimization
  • Concept of the Digital Twin

Exercise: Optimization Assessment

Session 11: Maintenance Strategies:

  • Run to Failure Maintenance (RTF)
  • Corrective Maintenance (CM)
  • Preventive Maintenance (PM)
  • Predictive Maintenance (PdM)
  • Prescriptive Maintenance (RxM)
  • Elimination – Improvement Projects

Session 12: Predictive Maintenance and Machine Condition

  • Equipment Failures and the P-F Curve
  • Application of Condition Monitoring

Exercise: Asset Condition Assessment 

Session 13: Overview of Key Performance Indicators – Control of the Maintenance Process

  • Overview of Key Performance Indicators (KPIs)
  • Overall Equipment Effectiveness (O.E.E.)
  • Strategic and Tactical-Focused Performance Indicators
  • Scorecards and Reporting

Session 14: Impact Driven Asset Management® (IDAM)

  • Operations in a Complex Environment and the Sea of Detail
  • Impact Driven Asset Management® Model
  • Machine Map (Line of Sight)
  • Stages on the Drive to Peak
  • Reaping the benefits of Impact Driven Asset Management®

Session 15: Group Discussion: Utilising the Knowledge Gained

  • Management of Change
  • The Next Step: What is yours?

WHO SHOULD ATTEND:

Head of Department, Managers, Team leaders, Foreman, Senior Technicians From

  • Reliability
  • Maintenance & CMMS
  • Operations
  • Plant
  • Technical
  • Engineering
  • Utilities
  • Asset Management
  • Works

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