The Maintenance Management Framework describes and reviews the concept, process and framework of modern maintenance management of complex systems concentrating specifically on modern modelling tools (deterministic and empirical) for maintenance planning and scheduling. It presents a new perspective of maintenance management by focusing on the course of maintenance actions, presenting a structure that ensures proper support for current maintenance managers, clarifying the functionality that is required from information technology when applied to maintenance and the functions of modern maintenance engineering and creating a set of practical models for maintenance management planning and scheduling.

Upon successful completion of this course, the delegates will be able to:

• Gain an comprehensive knowledge on the maintenance management framework
• Define and characterize maintenance management as well as designing methods and dealing the models with maintenance
• Apply basic analytical techniques which have proved valuable in solving practical maintenance problems focusing on critical equipment, analyzing failure data, system availability assessment, etc.
• Understand basic management principles and techniques such as object setting, organizational modeling, work measurement, etc.
• Distinguish modern condition monitoring techniques
• Develop a logical approach to the formulation of a maintenance strategy

These course will be beneficial for engineers and professionals involved in: maintenance management, maintenance engineering, operations management, quality, etc. It will also be of interest to graduate students and researchers in this field.

Day 1:

Maintenance Management Definition and Characterization

Definition of Maintenance Management

·         A Definition of Maintenance Management

·         Effectiveness and Efficiency of Maintenance Management

·         Maintenance Objectives, Strategy and Responsibilities

·         Strategy Implementation at the Three Levels of Activity: Strategic, Tactical and Operational

Maintenance Management Characterization: Process, Framework and Supporting Pillars

·         A Reason for MM Characterization.

·         The Maintenance Management Process.

·         Maintenance Management Framework

·         Functions of the MM Supporting Pillars

Basic Concepts for Complex Systems Maintenance

The Failure Concept

·         Failure Event and Related Terms.

·         Fault State and Related Terms

·         The Maintenance Time 

Day 2:

Failure Models

·         The Importance of Failure Data.

·         Basic Functions to Model Failures

·         Empirical vs Theoretical Failure Distribution Functions

·         Weibull Distribution Function and Weibull Analysis

·         Weibull Analysis

The Maintenance Concept

·         Maintenance Types

·         Maintenance Activities

·         The Indenture Level.

·         The Maintenance Level

·         The Maintenance Line or Echelon.

·         The Maintenance Policy

Basic Maintenance Models

·         Introduction to Maintenance Policy Modeling

·         Total Replacement Models

·         Replacement Models with Imperfect Maintenance (IPM).

·         Shock Based Replacement Models

·         Inspection Models

Developing the Maintenance Management Framework

A Review of Key Decision Areas in Maintenance Management Modeling

·         Introduction

·         A Generic Model for Maintenance Management.

·         Definition of Maintenance Objectives and Strategy

·         Asset Priority and Maintenance Strategy Definition

·         Immediate Intervention on High Impact Weak Points.

·         Design of the Preventive Maintenance Plans and Resources

·         Preventive Plan, Schedule and Resources Optimization

·         Maintenance Execution Assessment and Control

·         Asset Life Cycle Analysis and Replacement Optimization

·         Continuous Improvement and New Techniques Utilization

Day 3:

Definition of Maintenance Objectives and Strategy

·         Introduction

·         BSC and Maintenance

·         Proper Selection of Maintenance KPIs

·         From Key Performance Indicators to Functional Indicators

Criticality Analysis for Asset Priority Setting

·         Introduction

·         Criticality Analysis Using Qualitative Techniques

·         Criticality Analysis Using AHP

·         Case Study: AHP Applied to the Petrochemical Plant.

·         Maintenance Strategy Definition

A Method to Design the Maintenance Plan

·         An Introduction to RCM History.

·         RCM Concept

·         RCM Implementation

·         Failure Mode and Effect Analysis (FMEA).

·         RCM and the Hidden Failure Modes

·         Selection of Maintenance Activities Within RCM

·         Concluding Remarks

Day 4:

Models to Deal with Maintenance Capacity Planning.

·         Models for Maintenance Resources Management

·         Maintenance Staff Planning and Scheduling.

·         Maintenance Materials Requirements Planning.

·         A Model for Maintenance Contracts

Models to Deal with Maintenance Activities Planning

·         Markov Processes Models

·         Maintenance Optimization Models for Markovian Processes

·         Semi-Markov Process Models for Planning

Models to Deal with Maintenance Scheduling Issues

·         Introduction to the Maintenance Scheduling Process

·         CPM and PERT Methods

·         Maintenance Scheduling and Cost Analysis Methods

·         Using Monte Carlo Simulation Modeling for the PM Scheduling Problem

 Overall Maintenance Management Assessment

·         Introduction

·         Time Variables Characterization

·         Definition of Common Time-related Measures

·         Measuring Item Operational Dependability.

·         Maintenance Management Effectiveness Assessment

·         Maintenance Management Efficiency Assessment

Day 5:

Failures Impact on Life Cycle Cost Analysis

·         Introduction

·         Basic Elements of the LCCA.

·         Cost Characterization in Different Phases of the Equipment Life Cycle.

·         Reliability Impact on Life Cycle Cost

·         Models to Assess Reliability Impact on LCCA.

·         Case Study

·         Concluding Remarks

Maintenance Continuous Improvement through Organizational Efficiency

·         Introduction

·         Creating People Ownership of the Manufacturing Process.

·         Introducing Autonomous Maintenance (AM)

·         Pursuing Overall Organizational Effectiveness.

·         Maintenance Planning and Maintenance Quality

·         Early Equipment Management for Maintenance Prevention

·         Improving Maintenance Through Education and Training

The E-maintenance Revolution

·         Introduction

·         Factors for the Emergence of E-maintenance

·         The E-maintenance Capabilities

·         Challenges for E-maintenance

·         State of the art in E-maintenance

·         Concluding Remarks

·         E-maintenance New Terminology

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session