Effective Maintenance Management, Planning and Work Control

Introduction:

Effective Maintenance Management is the hub of a well-functioning maintenance organization. For maintenance to work, many other systems need to work well. Most importantly work identification of what to do and how to do it.

Focus is directed on concepts of maintenance and reliability management, Root Cause Analysis, and establishing a healthy maintenance program. The program focuses on various aspects of analytical techniques which have proved valuable in maintenance planning and scheduling. We also cover the Human Factor from many sides.

This program is designed to transfer knowledge and to be a stimulating experience. It is highly interactive with many discussions, group activities and case studies.

Participants can share examples from their own experience based on the new methodologies and work in teams with other participants to locate problems and develop actions for improvement.

Course Objectives:      

• Understand Maintenance Management basics
• Understand and use Root Cause Analysis – RCA – techniques to find root causes and/or resolve execution issues (in Planning and Scheduling)
• Develop the skills needed for effective planned maintenance program
• Define and prioritize maintenance actions based on analysis for proper planning
• Understand all maintenance cost elements
• Understand holistic maintenance methodologies and their application
• Develop and implement KPI’s and benefits tracking tools for Planning and Scheduling
• Developing and implementing an effective maintenance program

Course Content:

Introduction to Maintenance Management

• Generations of Maintenance
• Types of Maintenance (Corrective – Preventive – Predictive – Proactive)
• Pre-requisites to different maintenance types
• Modern Maintenance Methodologies (RCM – TPM – LEAN)
• How to choose the Maintenance type and strategy

A closer look at maintenance types

• Prerequisites for Break-down and Corrective Maintenance
• Preventive Maintenance
• Condition Monitoring as the maintenance breakthrough
• Proactive Maintenance

Key Performance Indicators (KPIs) in Maintenance Management 

• Selecting Key Performance Indicators
• There are several rules to follow in applying metrics
• What is Benchmarking?
• Examples and statistical analysis basics

Root Cause Analysis: The core of maintenance

• What RCFA is and why it is done?
• Failure Analysis Methods
• 5 Whys technique
• FMEA Procedure
• The Ishikawa Diagram
• Fault Tree Analysis
• Pareto Charts
• Human decision cycle and possible deviations

Total Productive Maintenance (TPM)

• Engineering, Production and Maintenance teams integration
• Objectives of TPM
• Overall Equipment Effectiveness, OEE
• 5S
• The pillars of TPM

Maintenance Tasks in TPM and RCM

• RCM as a holistic Maintenance Methodology
• TPM as holistic Maintenance Methodology

 Cost in Maintenance

• Spare Parts and stores, the ABC analysis
• Maintenance Budget elements

Maintenance Planning and Scheduling

• Measuring Workload
• Measuring Capability
• Essential planning parameters for perfect maintenance job execution
• Planning Principles
• Scheduling Principles
• Periodic Maintenance Scheduling (Daily – weekly – other)
• Teams in Maintenance
• KPIs to measure effectiveness