Implementation Integration and Management of Predictive Maintenance

The Result
Organizations that manage the condition and optimise the performance of equipment in the area of Maintenance are consistently able to better compete on the global stage. The participants and their teams are better positioned to positively influence the organization with innovative ideas and techniques that in turn produce a higher performing organization.

The Benefits
Individuals exposed to this training will develop expertise in the area of developing a Predictive Maintenance strategy through a project-based implementation and maintaining that strategy through good management techniques. They will learn why the best companies in the world see Predictive Maintenance as the key to delivering optimal production functionality by securing a thorough knowledge of equipment condition.

The Course
Predictive Maintenance is one of several techniques which are critical for a successful company and an integral part of maintenance management strategies such as RCM, RBM TPM, and even 6-Sigma. This comprehensive 5-day programme has been designed to benefit both qualified new professionals as well as experienced professionals who may be involved in the rollout of a new Predictive Maintenance system or auditing an existing system. It covers all the steps required in developing a successful Predictive Maintenance programme from initial recognition of a problem, through management approval and system development until a well-managed Predictive Maintenance system is in place and operational.

Course Objectives

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

• Provide a step-by-step guide to developing a predictive maintenance system starting with foundations and building up to best practice that will deliver maximum business benefits
• Provide opportunities to discuss the implementation and integration within the production environment
• Provide an opportunity to learn these concepts through practical exercises

Who Should Attend?

This course is recommended to all Maintenance, Reliability, Engineering and technical support staff especially including leadership and management.

Course Outline

Introduction

• Overview identifying objectives and goals
• Associate the delegates to teams for workshop activities
• Introduction to Predictive Maintenance technologies

Identify the Problems

• Basic reliability overview with statistical analysis of rotating equipment
• Pareto analysis and identification of bad actors
• Cause Mapping & FMEA

Prepare the solution for management

• Cost analysis of PDM –v- Status Quo
• Resource analysis
• Prepare the presentation to management for budget authorisation

Design a project to implement the initial stages such as software installation, equipment demographic analysis etc.

Potential Failure Analysis (PFA)

• Identify the failure mechanisms
• Identify suitable measurement technologies
• Prepare detailed PFA’s for the subject equipment

Acquire the Resources

• Prepare technical requirement specifications
• Vendor/equipment selection
• Define manpower requirements & job descriptions
• Define and acquire logistical support

Define the project

• Software tools
• Equipment demographic analysis
• PERT & GANTT charts
• Resource levelling

Manage the project and the capital budget.  This stage involves periodic progress reports to management.

Roll out the project

• Change management
• Define the pilot project area
• Post pilot rollout

Continuous Improvement

• Training
• Procedures
• PFA as part of ISO 9000

Project Progress Reporting

• Functional –v- operational reporting (project)
• Routines, procedures, processes
• Define progress reports (budgetary & technical)

Handover of the project to the operational division.  At this point we have to consider how to integrate the operational aspects of the new way of working so that the production and maintenance teams are involved.

Work Practices

• Technical qualification
• Functional responsibilities
• Functional –v- operational reporting (routine)
• PDM work flow

Reporting

• Define report content
• Getting the recommendations to where they do most good
• Overview reports

Continuous Improvement

• Alarm triggers
• Case history reviews
• PFA modification

Develop Key Performance Indicators so that managers can maintain control of the process.

CMMS Integration

• CMMS requirements
• Operational planning

Key Performance Indicators

• Reliability & statistics – MTBF, Reliability etc.
• Work request backlog analysis
• Customer feedback analysis
• Cost analysis

Course Methodology

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

Course Fees

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

Course Timings

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