Establishing Effective Preventive and Predictive Maintenance Programs

Introduction:

CMMS (Computerized Maintenance Management System) plays a vital role in enhancing productivity and performance within an organization. These electronic systems are designed to plan, schedule, and record maintenance and repair needs, relying on computer technology to improve operational efficiency.

A Need for Data Management and an Information System Strategy

To ensure effective data management, baseline information systems must be established before initiating the data build. Without these systems, baseline data can be compromised due to inefficient processes and confusion during implementation. A robust Knowledge Management and Information System strategy is essential, particularly for ADB-funded projects focused on privatization and commercialization. One of the primary challenges leading to data integrity issues within CMMS is the absence of consistent rules.

Achieving CMMS data integrity can be distilled into three steps: awareness, education, and accountability. This course on CMMS Data Integrity in the Oil and Gas Industry emphasizes the establishment of CMMS data during the pre-operational stage and executing comprehensive data cleansing of equipment and spare parts records, particularly in oil and gas software systems. The course outlines specific aspects of data builds for new systems and critically appraises existing CMMS information. It also covers quality assurance assessments and the workflow of data migration.

Understanding how to achieve data stewardship is particularly crucial in the oil and gas sector, where data is vital to operational processes. This requires a comprehensive and consistent approach to ensuring data integrity through best practices in CMMS data capture, timely audits, and corrective measures for any discrepancies.

Objectives:

By the end of the CMMS Data Integrity in Oil and Gas training, participants should be able to:

• Use CMMS terminal terminology
• Apply effective data entry techniques
• Incorporate principles of data integrity
• Extend data quality
• Manage security and access controls
• Prepare and analyze reports
• Engage in practical and simulated activities
• Receive continuous assistance and assessment

Training Methodology:

• Interactive verbal engagement presentations
• Group interactions
• Case incidents
• Simulation of real situations
• Review from structuralists
• Focus groups
• Role reversal methods

Course Outline:

Unit 1: Introduction to CMMS Data Build

• Everyday challenges encountered in building quality data
• Composition of CMMS data and processes
• Upgrades to the CMMS version and final evaluation
• Comparing efficiency: Microsoft Excel vs. Microsoft Access
• Application of Microsoft Access
• Exercises in spare part cataloguing
• Basics of MS Access: tables, queries, reports

Unit 2: Maintenance & Spares Coding

• Approaches to criticality for equipment and spares
• Equipment class
• Failure classes
• Shutdown codes
• Work order priority codes
• Developing the failure coding structure
• Exercise: Failure code structure

Unit 3: Building the Asset Register

• Building processes
• Developing guides and standards
• Naming and numbering conventions
• Groups maintainable
• Performing quality checks
• Equipment attributes

Unit 4: Building the Spares Database

• Building processes
• Developing guides and standards
• Naming and numbering conventions
• Quality of data checks
• Determining inventory levels
• Exercise: Register of building spares

Unit 5: Building the PM Data

• Introduction including definitions
• Maximo or SAP: terminologies used
• Creating generic strategy guides (including FMEA-based)
• Developing effective tasks
• Job plan forms
• Routes: linking PMs to tags
• Quality checks
• Exercise