TRAINING COURSE: Maintenance and Reliability Management

Work identification and prioritization: Machine failure and Root Cause Analysis

• 3.1. Why Machine Failure?
• 3.2. Understanding and identification of Failure Modes
• 3.3. Understanding the importance and effect of prioritization of work
• 3.4. Why Root Cause Analysis techniques are building blocks of a successful Maintenance Organization
• 3.5. Failures Modes and Effects Analysis Methodology – FMEA
• 3.6. Other RCA tools
• 3.7. Case Studies

Basic tools for Maintenance Program success

• 4.1. Technical report writing – what is not documented is lost!
• 4.2. The basic concepts of outsourcing a maintenance task
• 4.3. Basics of Data Analysis and representation
• 4.3.1. Using your data to get information – Data filtering, sorting, and credibility
• 4.3.2. Using your information to build knowledge – Knowledge base
• 4.3.3. Basics of Statistical analysis in maintenance 

What is your Maintenance Management System?

• 5.1. Principles of Maintenance Management
• 5.2. Reliability Centered Maintenance, RCM
• 5.2.1. Basic concept
• 5.2.2. Application
• 5.3. Total Productive Maintenance, TPM
• 5.3.1. Basic concept
• 5.3.2. Application
• 5.4. Visual Management and
• 5S: A base for effectiveness, efficiency, and success
• 5.5. What is Overall Equipment Effectiveness (OEE)?
• 5.6. Applying Risk Management to assist in work prioritization
• 5.7. Computerized Maintenance Management System, CMMS
• 5.7.1. Basic concepts of CMMS
• 5.7.2. Choosing the suitable CMMS for your organization needs

Maintenance Planning

• 6.1. Identifying and Measuring workload and the concepts of resources allocation
• 6.2. Control Absenteeism, tardiness and overtime
• 6.3. Planning Principles 6.3.1. The tasks to be implemented
• 6.3.2. The tools of performing the tasks
• 6.3.3. The working environment
• 6.3.4. Authorization of works/tools/accessibility
• 6.4. Role of Planner
• 6.4.1. The characteristics of the person
• 6.4.2. The needed skills of the planner
• 6.4.3. The inputs and the outputs
• 6.5. Creating and managing the Maintenance Plan based on multiple time segments (Annual, monthly, weekly, Daily)
• 6.6. Understanding and using of Work Orders Management System 

Maintenance scheduling

• 7.1. Understanding the difference between Planning and scheduling
• 7.2. Scheduling Principles
• 7.2.1. The tasks to be implemented
• 7.2.2. The tools of performing the tasks
• 7.2.3. The working environment
• 7.2.4. Authorization of works/tools/accessibility
• 7.3. Scheduling techniques based on specific parameters (urgency – criticality – cost – internal client requirements – resource allocation – etc.)
• 7.4. Periodic Maintenance Scheduling (Daily – weekly – other)
• 7.5. Role of Scheduler
• 7.5.1. The characteristics of the person
• 7.5.2. The needed skills of the planner
• 7.6. Maintenance schedule compliance
• 7.7. Effective methodologies of backlog management

Continuous improvement in Maintenance Management

• 8.1. Learning from past to improve future in Planning and Scheduling
• 8.2. Losses in a system: The Lean manufacturing methodology
• 8.3. Inconsistency in performance: The 6 Sigma methodology
• 8.4. Lean Six Sigma and its application in maintenance and reliability 

Understanding Cost in Maintenance (according to time availability)

• 9.1. Elements of Cost in owning and operating machinery and production lines
• 9.2. Life Cycle Costing, LCC and Total Cost of Ownership, TCO
• 9.3. Managing your spare parts through the effective ABC Stock Analysis process