Modern process and manufacturing industries are complex and capital intensive. Today’s competitive global marketplace requires them to be maintained so as to maximize uptime and minimizing operational costs. This course is designed to provide pertinent information and practical insight with Best Practices concepts about Maintenance & Reliability management to improve the performance of machines and enhance their reliability.

How to minimize the costs associated with equipment downtime and loss of production by implementing these practices.

Life-cycle costs include cradle to grave costs converted economic models. For most of plant and equipment’s the initial purchase price of the equipment is a small percentage of the total costs associated with maintenance costs, failure costs and downtime costs.

This course covers how to reduce failure of equipment and increase the reliability and the wellness of the plant overall. The course discusses the idea of using maintenance methods to minimize the Life Cycle Cost and how to develop a strategic reliability plan. The course will be interactive covering extensive case studies and real-life situations.

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

• Acquire knowledge on asset life cycle and maintenance management and modern maintenance practices
• Distinguish the maintenance levels and priorities
• Apply equipment criticality analysis and work prioritization
• Identify maintenance types that includes preventative, corrective and predictive
• Identify best practices drawn of different industries
• Apply reliability improvement techniques
• Learn the PLAN, DO, REVIEW cycle of continuous improvement
• Draw the most appropriate maintenance plans
• Gain exposure to current and emerging trends in maintenance and reliability as it relates to process and manufacturing  industries
• Schedule maintenance activities
• Understand life cycle cost (LCC) concepts
• Determine components of life cycle cost
• Recognize the impact of maintenance costs and downtime costs on life cycle cost strategies for extending operating life
• Reduce overall Life Cycle costs

This course is highly recommended to all maintenance, reliability engineering, plant engineering and technical support staff including maintenance foremen and supervisors. The course is designed for anybody associated with plant maintenance and those who wish to gain overview into modern maintenance & reliability management with no previous formal training will also find this course useful.

Day 1:

·         Introduction

·         Introduction to maintenance

·         The six purposes of maintenance

·         To know about maintenance levels and priorities

·         Equipment criticality analysis and work prioritization

·         Plant and equipment life cycle

Day 2:

·         Maintenance Types – Preventative, Corrective, Predictive

·         Choosing of maintenance type

·         Maintenance Best Practices

·         Maintenance by Plan vs. Maintenance by Default

·         Building a maintenance management plan

·         When and how much maintenance?

Day 3:

·         Measuring Plant & Equipment Performance

·         Set Standards and Standardize their Use

·         Using Condition Monitoring to Optimize Availability

·         Building Credible Preventive Maintenance Procedures

·         Condition-based maintenance techniques

·         Maintenance and Reliability interdependence

Day 4:

·         Turnarounds, Shutdowns and Outages

·         Equipment Reliability

·         Equipment reliability and availability

·         Root cause Analysis ( RCA)

·         Failure mode effects analysis (FMEA) fundamentals

·         A Roadmap for Reliability Improvement

Day 5:

·         Reliability-Centered Maintenance/ Preventive Maintenance

·         Optimization

·         Reliability of Series Work Process

·         Parallel Process Reliability

·         focusing reliability improvement

·         FMECA as a method for analyzing, prioritizing and avoiding potential equipment failures

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