Maintenance & Reliability Best Practices
Course Code: EM20
Course Objective
- Understand the concepts of costs, capital, profit and ROI
- Understand the cost impact of unanticipated failure
- Apply proactive policies to reduce future maintenance costs
- Structure and analyse failure data to reduce repetitive failures
- Identify root causes of unanticipated failure costs
- Reduce resource costs through efficient work management practices
Target Audience
- Planners
- Supervisors
- Engineers
- Reliability Engineers
- Maintenance Team Leaders and Managers
- Operations Team Leaders and Managers
Course Outline
DAY 1: Equipment Life-cycle Cost Introduction
- Definitions of Reliability, Maintenance & Asset Management
- The Concept of Costs, Capital, Profits and Return On Investment
- The ‘Asset Healthcare Model’
- Key Areas of Asset Management
- Open Discussion Sessions
DAY 2: Cost Factors and Causes
- The Real Cost of Unanticipated Failure
- Asset Performance Standards
- The Forms of Asset Failure and Degradation
- The Causes and Nature of Asset Failure and Degradation
- The Effects, Cost and Risks of Asset Degradation
- Practical Application and Discussion of Case Study
DAY 3: Breaking the Cycle of Degradation and Costs
- Programmed Maintenance
- Programmed Maintenance Intervals
- Condition-based Maintenance Intervals
- Implementing Optimised PM Programs
- Optimizing spares to support the Maintenance Program
- Practical Application and Discussion of Case Study
DAY 4: Cost Reduction through Defect Elimination
- Failure Data Collection and Analysis
- The Impact of Chronic Failures vs. Intermittent Failures
- Focus improvement through Pareto Analysis
- Quantify losses in Life Cycle Terms
- Rigorous Root Cause Analysis Techniques
- Root Cause Analysis Case Study
- Discussion of Software and Templates to Support Analysis
DAY 5: Work Management converts Strategy to Practice
- Work Identification and Defect Reporting
- The Importance of Backlog
- Planning for Quality and Reliability
- Capacity Planning
- Scheduling for Efficiency
- Work Logistics and Preparation
- Checklists and Practical Aspects Work Quality Control
- Final Discussion and Evaluation
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