Optimized Maintenance Management

Introduction:

The most progress-oriented industrial companies are moving away from reacting – i.e., when something breaks, and you fix it – to planning, a key aspect of advanced maintenance management systems. Such a shift requires well-coordinated and executed activities in many areas.

This course in Optimized Maintenance Management provides essential knowledge and skills for participants to achieve optimal performance of equipment, structures, and systems, and improve maintenance procedures to gain maximum return on investment. Maintenance managers will master the methods for increasing asset utilization rates, decreasing costs and downtimes, and ensuring high safety and quality standards.

The course will cover the technologies and methods of modern maintenance management, presenting both the theory and practice of building effective maintenance policies.

Objectives:

Upon completion, participants of this Optimized Maintenance Management course will:

• Gain a proper appreciation of the principles governing the Asset Management framework for optimizing maintenance.
• Decide on appropriate maintenance KPIs and compose a balanced scorecard for the maintenance department.
• Assess the Asset Management capability of the organization and design a strategy for enhancement.
• Examine organizational and managerial challenges encountered in operationalizing comprehensive Risk-Based Maintenance systems.
• Appreciate Life Cycle Management with regard to Systems Engineering and RAMS in support of Life Cycle Management.
• Compute the Life Cycle Cost of a particular asset.
• Explore modern methods and ideas in Predictive Maintenance and Smart Maintenance.

Training Methodology:

• Facilitation by experts through lectures.
• Real-life situations using case studies.
• Group discussions.
• Learning by doing – workshop approach.
• Situation analysis of given scenarios.
• Experience sharing.
• Role-playing activities.
• Management by objectives.
• Problem-solving exercises.

Course Outline:

Unit 1: Conceptual Basics for Managing and Optimizing Maintenance Activities:

• Understanding Asset Management as a business.
• Typology of Asset Management Modelling.
• Defining the Strategy Trampolines.
• Strategic Line of Sight.
• Policy as an Asset Management Framework, and Asset Management Strategy.
• Framework for developing Strategic Asset Management Decisions.
• The place and relevance of Maintenance Management.
• Levels and roles of Asset Management in strategic, tactical, and operational management.
• Booklet 50.006 – Safety Level of Structures- Asset Management System (International Standard).

Unit 2: Judging Asset Management Maturity as Ground to Enhance Maintenance:

• Evaluation.
• KPI measures, instrumentation, and dashboards.
• Appraisals and international criteria.
• Terms of Reference for the Asset Management Maturity Matrix.
• Asset management technique/infrastructure gap analysis (ISO 55000 implementation).
• Self-assessment methodology for self-assessors.
• Outline of the Maintenance Improvement Road Map.
• Asset Management Improvement: A business case for cost/benefit analysis.
• Implementation issues.

Unit 3: Risk in Relation to Assets and the Associated Maintenance Approach – Risk-Based Maintenance (RBM):

• Calibrating maintenance based on critical failures – marking risk evolvements.
• Risk on an organizational level.
• Risk matrix, risk register.
• Risk on an asset level.
• Failure behavior of systems.
• Choosing appropriate maintenance tasks for assets using a Risk-Based approach.

Unit 4: Life Cycle Management:

• Life Cycle Management.
• The life cycle of an asset.
• Demand forecasting.
• Creation and acquisition of assets.
• Systems engineering approach.
• RAMS (Reliability, Availability, Maintainability, and Safety) requirements – methodologies.
• Life Cycle Costing (LCC).
• Disposal and replacement – Life Extension (Asset Rationalization).

Unit 5: Smart Maintenance – Managing Maintenance and Asset Care for Optimum Performance:

• Understanding principles of Predictive Maintenance (PdM).
• Overview of relevant PdM technologies.
• Smart Maintenance – measuring asset performance with modern data technology.
• Data analysis aspects.
• Optimization aspects – optimizing the maintenance strategy.
• Using decision support tools.