Mini Master: Maintenance Management and Technology Insights (10 Days)

Introduction:

Success in Maintenance Best Practices, both personally and organizationally, hinges on a thorough understanding of Maintenance Management and Technology. This comprehensive training course is tailored for both newcomers and seasoned professionals aiming to enhance their skills. The curriculum begins with foundational concepts and progresses to complex structures, equipping participants with the knowledge to build a robust maintenance framework. The course emulates MBA-level instruction through interactive discussions, team activities, and practical applications.

Objectives:

By the end of the Maintenance Management course, participants will be able to:

• Master maintenance best practices from foundational to advanced levels, with clear examples of expected business benefits.
• Explain and apply optimization techniques for maintenance practices.
• Demonstrate the application of maintenance best practices in various scenarios.
• Reinforce learning through practical exercises.
• Implement maintenance optimization techniques effectively.
• Identify and explain equipment failures and their impacts on operational efficiency.
• Develop a comprehensive maintenance strategy for static and rotating equipment, including routine and non-routine inspections.

Training methodology:

• Interactive Workshops
• Case Studies
• Discussion Sessions
• Hands-On Exercises
• Simulation Tools
• Expert Lectures
• Team Activities

Course Outline:

Unit 1: An Overview of Key Maintenance Work Processes

• Introduction to Maintenance Management
• Key Terms and Definitions
• Types of Maintenance: Reactive, Planned, and Improvement
• Effectiveness of Preventive and Proactive Actions

Unit 2: Maintenance Management Systems

• Maintenance Planning and Control
• Computerized Maintenance Management Systems (CMMS)
• Key Performance Indicators (KPIs) for Maintenance Programs

Unit 3: Preventive Maintenance and Mechanisms

• Organizational Structure and Policies for Maintenance
• Planning and Implementing Preventive Maintenance Programs
• Reliability-Centered Maintenance Principles

Unit 4: Maintenance Logistics and Costs

• Maintenance Spares and Logistics
• Cost Estimation and Forecasting for Maintenance
• Life Cycle Cost Analysis

Unit 5: Maintenance Team Work

• Coordination Among Engineering, Production, and Maintenance Teams
• Challenges in Integrated Team Environments
• Strategies for Motivation and Self-Control
• Team-Based Continuous Improvement Concepts

Unit 6: Machinery Failure and Inspection-Based Analysis

• Analysis of Cavitation in Pumps, Turbine Tripping, and Compressor Surging
• Wear Mechanisms: Fatigue, Fretting, and Corrosion
• Solutions for Balancing, Alignment, and Mounting Issues

Unit 7: Causation Analysis and Reliability

• Basic Statistics and Reliability Models
• Case Studies of Major Failures in Process and Oil & Gas Industries
• Principles of Root Cause Analysis

Unit 8: Statistical Failure Analysis and Reliability

• Reliability Definitions and Guidelines
• Hazard Function and Bathtub Curve Analysis
• Weibull Analysis Techniques

Unit 9: Condition-Based Maintenance

• General Purpose CBM
• P-F Curve Review
• Vibration, Temperature, Acoustic Emission, and Lubricant Monitoring

Unit 10: Decision Analysis in Asset Management

• Evaluation of CMMS Management
• Asset Management Frameworks
• Decision-Making Methods
• Integration of RCM, TPM, and CBM Methods

Conclusion:

Participants seeking to advance their professional standing can pursue certification in maintenance management. This certification will validate their expertise in maintenance best practices and modern solutions, demonstrating their commitment to excellence in their organizations.