Implementing Effective Preventive & Predictive Maintenance

Reliability Centered Maintenance (RCM) finds its roots in the early 1960s, when the initial development work was performed by the North American civil aviation industry. “Maintenance Steering Groups” was put together to formulate maintenance strategies that was cost effective, and able to keep their aircraft in a safe operable condition. Over the centuries this technique was formulated and refined into the principle of “Reliability Centred Maintenance” which is today widely used in industries such as petroleum, chemical and pharmaceutical companies, electric utilities, food processing, railways, government agencies, armed forces, facilities and other firms and industries.

RCM is a systematic and structured process used to decide what must be done to ensure that any physical asset, system or process continues to do whatever its users want it to do. It is taking into consideration the primary performance parameters of the asset, possible failure mode and consequence and lastly a suitable failure management policy.

This course is designed to familiarize you with the principles and the process of implementing a RCM program. It will help you to apply the rules of RCM through cross-functional review groups in order to produce robust and cost effective asset management programs, by applying the four maintenance strategies, i.e. corrective, preventive, predictive and pro-active.

Course Objectives

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

• Implement an effective preventive and predictive maintenance in all types of industries
• Apply proper systems in preventive and predictive maintenance programs generally used in industry according to standards
• Understand the principle of Reliability Centered Maintenance which is widely used in industries particularly in petroleum, chemical and other facilities
• Apply project initiation through planning and preparation, set-up review and selecting analysis for RCM
• Determine failures and root cause of failures, failure modes and effects and identify the consequences of failures
• Enumerate and select types of maintenance tasks through pro-active maintenance that includes scheduled restoration tasks, scheduled discard tasks and scheduled on-condition tasks
• Discuss types of predictive techniques and explain pro-active task as well as the implementation in preventive and predictive maintenance

Who Should Attend?

This course is intended for all maintenance managers, reliability engineers and technicians directly involved in maintaining and preserving the function of assets. Since the RCM process makes use of cross–functional groups as well as the fact that a lasting maintenance program can only be developed by maintainers and users of the assets, it is also recommended that operation/production personnel attend this course to ensure an effective RCM program. These should comprise consulting engineers, key leaders from each maintenance craft, maintenance managers/supervisors, operation specialists, planners, plant managers, reliability engineers/technician.

Course Outline

Day 1
Reliability Centred Maintenance (Rcm) – An Overview

• Evolution of maintenance
• History of RCM
• Classical RCM
• RCM2
• Streamlined RCM

Why Rcm For My Organisation

• Why RCM is different
• The new paradigms in maintaining assets
• What you should expect from RCM
• Who should do RCM

Day 2
Project Initiation

• Planning and preparation
• Setting up review groups
• Selecting facilitators
• Selecting the systems for RCM analysis ( Preventive to Predictive Maintenance)

Gathering And Breakdown Of The Basic Information

• Defining functions and performance standards
• Defining failure – functional failure
• Establish root cause of failures – failure modes
• Identify what happens if failure occurs – failure effect
• What is the consequence of failure (cost, throughput, quality, safety, environment and customer)
• FMECA

Day 3
Selecting Maintenance Tasks Through Pro–Active Maintenance (Pdm, Pm)

• Scheduled restoration tasks
• Scheduled discard tasks
• Scheduled on-condition tasks

Types Of Predictive Techniques Available

• “The Human”
• Vibration monitoring and analysis
• Thermography
• Oil analysis – rotating and transformers
• Ultrasonic
• Magnetic flux
• Dye penetrant
• Radiography
• MPI
• Eddy current

Day 4
If no pro-active task is available?

• When and how to do failure-finding (including RCA’s)
• When to redesign
• When to run to failure

Implementation

• Auditing the analysis
• Developing the maintenance program
• Continuous improvement
• KPI’s to measure success

Day 5
Practical Exercises

• Breakdown of plant into systems
• Completing a FMECA
• Selecting the appropriate tasks for different scenarios
• Developing the maintenance program – blue print

Course Requirement

“Hand’s on practical sessions, equipment and software will be applied during the course if required and as per the client’s request”.

Course Certificate

International Center for Training & Development (ICTD) will award an internationally recognized certificate(s) for each delegate on completion of training.

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