Equipment Maintenance and Replacement Optimization

Introduction

Globally recognized process and petrochemical industries have advanced their maintenance practices to enhance predictive maintenance management systems. This comprehensive approach involves thorough and ongoing examination of both stationary and rotating equipment components. The purpose of this training on optimization of maintenance and replacement decisions is to focus on effective stock control of spare parts, selecting suitable maintenance personnel, and exploring outsourcing options.

Utilizing reliability information optimizes Fitness for Service (FFS) evaluations, which guide decisions on whether to continue servicing, repair, or replace equipment. These decisions are crucial due to their economic and safety implications. An optimized system for maintenance and replacement decisions enhances strategic management efficiency.

The course aims to equip participants with the skills necessary for optimizing equipment maintenance and replacement strategies. Participants will learn various maintenance optimization techniques and acceptable standards for decision-making processes.

Objectives

By the end of the Equipment Maintenance and Replacement Optimization course, participants will:

• Assess the causes of equipment failure and its impact on reliability.
• Perform cost-benefit analyses of Preventive and Predictive Maintenance approaches.
• Apply maintenance strategies to improve existing practices.
• Determine optimal workforce size, spare parts inventory, and replacement planning.
• Conduct skilled cost-benefit analyses for maintenance and replacement decisions.
• Integrate safety considerations with repair or replacement strategies.

Training Methodology

• Simulation
• Group Work
• Interactive Activities
• Scenario-Based Learning
• Panel Discussions
• Project Work
• Simulation Game
• Behavioral Evaluation

Course Outline

Unit 1: Management of Physical Assets and Failure Analysis

• Introduction to Physical Asset Management
• Understanding Maintenance Management: Preventive/Predictive Approaches
• Equipment Failure Characteristics: Nature and Modes
• Failure Modes and Effects Analysis (FMEA)
• Failure Data Analysis through Weibull Distribution
• Advanced Statistical Methods: Censored Data, 3-Parameter Weibull, Kolmogorov-Smirnov Test

Unit 2: Management of Maintenance and Spare Parts Replacement

• Reliability and Availability: MTBF and MTTR
• Improving Reliability by Minimizing Downtime
• Measuring Maintenance Effectiveness
• Planning and Scheduling Maintenance and Spare Parts
• Spare Parts Management: Forecasting and Predicting Requirements
• Evolving Spare Parts Strategies

Unit 3: Equipment Inspection and Fitness for Service

• Monitoring and Inspecting Equipment at Specified Intervals
• Understanding Risk-Based Inspection (RBI) Approach
• Constructive and Commercial Use of Risk Evaluation Charts
• Improving Reliability with Timely Inspections
• Managing Inspection Work Load: Contents and Frequency
• Comprehensive Justification for Fitness for Service (FFS)

Unit 4: Economics of Maintenance, Repair, and Replacement

• Efficient Use of Maintenance Resources
• CMMS Optimization for Maintenance Workflows
• Ideal Crew Size and Ratio Terms
• Economic Considerations for Equipment Restoration or Replacement
• Reasons for Outsourcing and Subcontracting Maintenance
• Cost Analysis Associated with Equipment Replacement

Unit 5: Total Productive Maintenance and Safety

• Capital Investment and Maintenance Strategies for Maximizing Returns
• Concepts of Total Productive Maintenance (TPM) Management
• Integrating Safety Management with Maintenance Work
• Use of KPIs and OEE Metrics: Leading vs. Lagging Performance Indicators

Conclusion

This course on optimizing equipment maintenance and replacement decisions will provide participants with a thorough understanding of how to apply equipment optimization techniques and maintenance strategies. By integrating these approaches into strategic decision-making processes, participants will enhance their ability to manage maintenance and replacement efficiently and effectively.