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Maintenance Management - Delivering Reliability in the Process Industries

Course Outline

  • What is the objective?
  • Why do things break? - Maintenance Theory
  • Patterns of Failure
  • Appropriate and inappropriate maintenance tasks
  • Approaches to improving reliability – an introduction
  • Failure Modes Effects Analysis
  • Reliability Centred Maintenance
  • Planned Maintenance Optimisation
  • Total Productive Maintenance
  • Root Cause Analysis
  • Definition and Control of tasks – ensuring tasks are done and done well
  • Measuring Reliability
  • KPIs & Measures
  • OEE and the Six Major Losses
  • Addressing the 6 Major Losses
  • Maintenance Planning & Control
  • Managing work arising
  • Job priority
  • Planning approaches
  • Downdays and planned maintenance periods – what is their purpose?
  • Determining the frequency
  • Types of task to schedule

Training Notes -

A full hardcopy set of slides and handouts will be given to delegates attending the course

Why Maintenance Management?

Maintenance Management is a distinct and specialised engineering discipline often overlooked or taken for granted but is critical for the efficient and productive operation of any facility.

This course is an introduction to maintenance approaches and theories which will equip the delegate to take a fresh look at the performance of the maintenance engineering department.

This may include:

  • Senior Engineering Managers
  • Departmental managers with maintenance responsibilities
  • Engineers and Section Engineers charged with maintaining plant and equipment
  • Engineering planners
  • Engineering first line supervisors

Maintenance for Reliability is different from Asset Integrity. The latter is about preventing a loss of containment or preventing uncontrolled releases of energy that could lead to a major accident or incident. Maintenance for Reliability is about ensuring the plant operates when called upon to produce product. So, while not as critical for process safety, it is nevertheless important to the viability of a business to have reliable processes and equipment. However, the safety drivers in our industry can often push reliability into the background.

Too often intuition and experience is used to come up with maintenance policies for items of plant. As was discovered by Nowlan and Heap in their seminal work on maintenance theory which led to the development of Reliability Centred Maintenance, intuition and experience can get it wrong.

Without an understanding of failure patterns and maintenance theory, efforts to improve reliability can result in minimal benefit, or even worsening performance.

This one-day course will begin with the fundamentals of maintenance – what is the objective? – and build from that point to look at a range of topics relevant to Maintenance Management (including maintenance theory) to support improving plant reliability and performance.

The course will be delivered in the context of maintenance in the Process Industries, drawing on specific case studies and industry specific experience.

We can also deliver this course in other industry specific contexts.