Maintenance - Best Practices

Module 1: Maintenance Management Best Practices: Systems, Tools & Techniques

An Overview of Key Maintenance Work Processes

• Introduction to Maintenance Management
• Definitions of key terms
• Types of Maintenance - Reactive, planned and improvement jobs, Preventive and Proactive
• Maintenance Planning and Scheduling

Preventive Maintenance and Maintenance Strategy

• Maintenance Organisation Structure and Policies
• Developing and Implementing a Preventive Maintenance Program
• Applying Reliability Based principles to Maintenance Strategy Development

Maintenance Logistics and Cost Control

• Managing Maintenance Spare Parts and Logistics
• Optimising Spare Parts Inventory Levels
• Maintenance Budgeting
• Controlling Maintenance Costs
• Introduction to Life Cycle Cost Concepts

Maintenance Team Work

• Engineering, Production & Maintenance Teams
• Benefits of Integrated teams
• Motivation and empowerment
• Total Productive Maintenance Concepts
• Implementing Team Based Continuous Improvement in Maintenance

Module 2: Maintenance Technology Best Practices: Inspection, Analysis & Monitoring

Failure of Machines and Inspection Based Failure Analysis

Causes of Machinery Failure

• Wear Mechanisms
• Fatigue
• Fretting
• Corrosion and Electrolytics

Fundamental Machine Problems

• Balance Problems
• Alignment Problems
• Machinery Mounting Problems

Component Failure

• Plain Bearings
• Rolling Element Bearings
• Couplings
• Seals
• Gears Drives
• Belt Drives

Statistical Failure Analysis and Reliability

• Job Feedback and the Importance of History Records
• Elementary Statistics
• Collection, Analysis, Representation and Interpretation of Statistical Data
• Reliability Models
• Maintenance Cost Optimisation

Condition Based Maintenance

The Condition Based Approach

• What to Monitor and Where
• Condition Monitoring Systems
• Trending of Monitored Data
• Frequency of Measurement
• Parameter Symptom Limits
• Remaining Life Prediction

Machinery Condition Monitoring

• General Purpose CM
• Thermal Monitoring
• Lubricant Monitoring
• The Essentials of Vibration Monitoring
• What is Vibration
• How to Measure Vibration
• Where to Measure Vibration
• How to Represent Vibration

Vibration Analysis

• Overall and Spectral Representation
• The Big Five Machine Faults
• Detecting Faults Using Vibration
• Diagnosing Faults Using Vibration