Effective management of physical assets is becoming a major necessity for companies to remain competitive in a global market place. This course is focused on providing a thorough understanding of Reliability Centered Maintenance and the crucial role it is now playing in determining the optimum maintenance program. Various approaches to performing RCM analysis are presented although emphasis is placed on a more streamlined and simplified, although still effective, approach to achieving an optimum maintenance program. An example system will be explored by means of various working sessions to give the participants a hands-on experience with applying RCM.

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

• Explore the components that comprise an effective maintenance program
• Understand the place of Reliability-Centered Maintenance in the business of maintenance and its role in determining the optimum maintenance program
• Review the history and principles of RCM along with the various approaches
• Present a methodology for applying RCM using examples and working sessions
• Understand what is needed to implement RCM and its results
• Understand the role of condition monitoring and information systems in the implementation of RCM

The course is intended for personnel involved with maintenance of equipment including supervisors, planners and engineers. It is of value both to those that are preparing to implement RCM and to those that are considering its use. It is also valuable to operations and design staff that interact with maintenance. Participants will receive a thorough overview of all of the basic components of RCM.

Day 1:

Introduction to Maintenance

·         What Is Maintenance:

o   Introduction

o   Components of maintenance

o   History of maintenance?

·         Current Approaches to Maintenance:

o   Total Productive Maintenance

o   Condition-Based Maintenance

o   Proactive Maintenance

·         Optimum Maintenance Program:

o   Maintenance planning approaches

o   Maintenance processes

Day 2:

Reliability Centered Maintenance

·         Introduction to RCM:

o   History of RCM

o   Principles of RCM

o   Benefits of RCM

o   RCM and risk

o   Types of maintenance tasks

·         The Nature of Failure:

o   What is failure?

o   The failure process

o   The failure mechanism

o   The bathtub curve?

·         The RCM Process:

o   Classical RCM process

o   Streamlined RCM process

o   Other approaches

o   RCM as a project

Day 3:

Reliability Centered Maintenance (cont’d)

·         Functional Failure Analysis:

o   Data gathering

o   System boundaries

o   Functions and performance standards

o   Functional failures

o   Working session

·         Failure Modes and Effects Analysis:

o   Failure modes

o   Failure effects and consequences

o   Equipment criticality, working session

·         Task Selection:

o   Failure causes

o   Applicable and effective tasks

o   Task logic tree

o   Cost benefit analysis

o   Working session

·         Implementation:

o   Task comparison

o   Task packaging

o   Redesign

o   Criticality checklist

o   Implementation planning

o   Project completion

o   Implementation

Day 4:

Application of RCM

·         Ongoing Role of RCM:

o   Organizational issues

o   The living program

o   Performance measures

·         Documentation and Information Systems:

o   Operating and maintenance documentation

o   Computerized Maintenance Management Systems

o   RCM analysis system

Day 5:

Application of RCM (cont’d)

·         Condition Monitoring:

o   Types of condition monitoring

o   Principles of effective monitoring

o   Computerized logging and monitoring

·         Challenge Your Paradigms:

o   Applying RCM in your situation

o   Working session

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