Achieving Maintenance Excellence (10 Days)

Introduction:

Industries worldwide are shifting from reactive maintenance ("fix-it-when-it-breaks") to predictive and preventive maintenance ("anticipate and fix-before-it-breaks") as part of a comprehensive Asset Management approach. This transition towards Maintenance Excellence involves structured and multi-dimensional actions. Despite the critical role of effective maintenance planning in asset management, many organizations still struggle with its implementation and realization of benefits.

Maintenance Excellence offers opportunities to enhance asset performance and maintenance processes, maximizing Return on Investment (ROI) while adhering to safety and quality standards. Organizations must understand the regulations and strategies for maintenance planning to optimize asset value.

The Creating Maintenance Excellence course equips participants with the skills to implement Maintenance Management Philosophy, combining theoretical knowledge with practical cases to achieve optimal results and increased profitability.

Objectives:

At the end of the Creating Maintenance Excellence course, participants will be able to:

• Understand the principles of Asset Management focused on optimizing maintenance.
• Design and standardize maintenance KPIs and management scorecards for performance.
• Evaluate organizational Asset Management maturity and develop an improvement roadmap.
• Recognize the relationship between risk and adopting Risk-Based Maintenance concepts.
• Explain how systems engineering and RAMS support life cycle management.
• Assess the Life Cycle Costs of assets.
• Apply new principles and practices in Predictive and Smart Maintenance.
• Set up and manage master data for asset maintenance.
• Develop and implement programmed maintenance schedules.
• Create task structures that meet safety, quality, and efficiency goals.
• Procure items for backlog work and develop work schedules with stakeholders.
• Produce performance reports highlighting areas of concern.

Training Methodology:

• Case Studies
• Workshops
• Interactive Simulations
• Group Discussions
• Scenario Analysis
• Expert Panels
• Project-Based Learning
• Role-Playing
• Data Analysis Exercises

Course Outline:

Unit 1: Introduction to Asset Management – A Framework for Managing and Optimizing Maintenance:

• Asset Management as a Business Process.
• Asset Management Landscape Model.
• Strategy Framework.
• Line of Sight.
• Asset Management Policy and Strategy.
• Strategic Asset Management Plan.
• Maintenance Management's Role.
• Asset Management at Strategic, Tactical, and Operational Levels.
• ISO 55000 – International Standard on Asset Management.

Unit 2: Assessing Asset Management Maturity as a Basis for Maintenance Improvement:

• Performance Measurement.
• KPI – Dashboard.
• Monthly Results Presentation: Leading and Lagging Indicators.
• Assessment against International Standards.
• Performance Management Frameworks.
• Asset Management Workbench (GAP Analysis ISO 55000).
• Self-assessment of Asset Management Equations.
• Identifying Obstacles to Improvement.
• Business Benefits of Asset Management Improvement – Cost-Benefit Analysis.
• Implementation Aspects.

Unit 3: Managing Asset Risks - Risk-Based Maintenance (RBM):

• Principles of Risk and Failure.
• Business Level Risk.
• Risk Assessment/Risk Priority Matrix.
• Asset-Level Risk and Failure Modes.
• Optimal Asset Maintenance Strategy Planning with Risk-Based Management.

Unit 4: Life Cycle Management:

• Phases of Asset Life Cycle.
• Sales and Revenue Forecasting.
• Asset Creation and Acquisition.
• System Engineering Standards and RAMS.
• Life Cycle Costing (LCC).
• End-of-Life and Disposal, Replacement, and Life Cycle Extension.

Unit 5: Smart Maintenance:

• Key Concepts in Predictive Maintenance (PdM).
• PdM Technologies: Applications and Benefits.
• Broadcasting Maintenance Information.
• Research and Optimization Aspects.
• Decision Support Tools.

Unit 6: The Building Blocks of a Modern Maintenance Management System:

• Asset Healthcare Model.
• Asset Master Data.
• Organization Master Data.
• Maintenance Logistics Planning.

Unit 7: Programmed Maintenance Development and Planning:

• Criticality Grading.
• Failure Modes and Effects Analysis (FMEA).
• Programmed Task Selection Criteria and Tools.
• CMMS Task Plans and Work Orders.
• Maintenance Task Procedures.

Unit 8: Work Management:

• Work Management Process Model.
• Defect Reporting and Notifications.
• Backlog Control.
• Capacity Planning and Resourcing.
• Consensus Scheduling.

Unit 9: Shutdown and Turnaround Management:

• Network Planning and Critical Path Scheduling.
• Resource Profiling.
• Balancing Resources and Schedules.
• Shutdown and Turnaround Progress and Control.

Unit 10: Performance Management:

• Establishing Performance Indicators and Data Sources.
• Management Operations Performance Measures.
• Asset Maintenance Performance.
• Cost Control Measures.
• Performance Measures at the Planning Stage.