Strategic Maintenance Planning: Approaches and Best Practices

Introduction:

To sustain profitability, effective maintenance is essential as it impacts equipment capacity, product quality, safety, health, environmental effects, and production costs. World-class maintenance not only enhances plant profitability but also boosts customer satisfaction, employee pride, and vendor relationships.

Achieving world-class maintenance involves proactive strategies that align with business goals and integrate technical and managerial elements at all organizational levels. This strategy should leverage cutting-edge methods and practices, ensuring effective maintenance management and minimizing lifecycle costs for both new assets and ongoing operations.

Objectives:

Upon completing this Strategic Maintenance Planning and Management course, participants will be able to:

• Recognize the role of maintenance in achieving business goals.
• Develop a structured approach for implementing systematic maintenance strategies.
• Understand the roles, processes, and procedures essential for organizational effectiveness.
• Define and use key metrics to evaluate management and technical performance.
• Enhance asset performance and ensure long-term maintenance success.

Training Methodology:

• Case Studies
• Workshops
• Simulations
• Group Discussions
• Project Report
• Game Techniques
• Hands-on Learning
• Role Play Exercises
• Panel Discussions

Course Outline:

Unit 1: Maintenance Objectives and Strategy

• Trends affecting maintenance
• Integration of maintenance in modern business strategies
• Cost reduction and effectiveness improvement
• Interpreting downtime costs
• Financial impact of maintenance
• Evolution of maintenance as a discipline
• History and types of maintenance
• Designing a lean maintenance policy
• Aiming for best maintenance management and reliability

Unit 2: World-Class Standards – Benchmarking Your Plant

• Maintenance performance measurement and benchmarking
• Conducting a maintenance audit
• Organizing and controlling performance excellence
• Application of Overall Equipment Effectiveness (OEE)

Unit 3: New Management Approaches

• Reliability-Centered Maintenance (RCM) analysis
• Introduction to Total Productive Maintenance (TPM)
• Life-cycle cost considerations
• Working with Computerized Maintenance Management Systems (CMMS)
• Challenges and failures in CMMS/MMS deployment

Unit 4: Optimizing Maintenance Organization

• Targeting operational excellence
• Creating a unified vision for operations and maintenance
• Assessing maintenance responsibilities
• Analyzing the 70/30 rule in maintenance and operational tasks

Unit 5: Contract Maintenance

• Revising maintenance management myths
• Enhancing maintenance techniques
• Case study analysis