Know About Your Trainer

Our trainer is a highly experiencedHis Industry Experience is more than 36 years which involved more than 26 years of experience in Oil and Gas industry in international leading companies (Shell, BP and Total joint venture companies) including more than 22 years in Maintenance Planning and Scheduling.He led several Teams such as Maintenance Planning and Scheduling Teams (thrice),
Asset Management Team, Asset Management System Project Team, and Reliability and Data Management Team.
He planned more than 40 major Shutdowns / Turnarounds and several major overhauls.

Who Should Attend This Training

This course is intended for personnel involved with maintenance and reliability of assets including:

Maintenance: Engineers, Planners, Supervisors, Section Leaders, Team Leaders, and Managers
Reliability: Engineers, Section Leaders, Team Leaders, and Managers
Operations and design staff who interact with maintenance
Personnel who are preparing to implement RCM and those who are considering its use.
This course is also suitable for project managers, project engineers, operations managers, shift managers, operations supervisors and people who are in training for these positions.
This course is also designed for contractors who want to contribute to the reliability performance of client assets.

What You Will Learn

DAY ONE

RELIABILITY AND MAINTENANCE JOURNEY TOWARDS EXCELLENCE

The big picture
What’s Reliability?
What’s Maintenance?
What’s the relation between Maintenance and Reliability
What’s the relation between Maintenance, Reliability and Asset Management?
What’s a reliable plant?
The benefits of implementing a reliability improvement program
How does a reliable plant maximize the value of its asset?
When should reliability and maintenance improvement start?
Understanding how Maintenance main maintenance strategies evolved and led to Reliability Centered Maintenance (RCM)
Reactive Maintenance
Run to Failure Maintenance
Corrective Maintenance
Preventive Maintenance
Condition Based Maintenance
Predictive Maintenance

DAY TWO

EXAMPLES OF RELIABILITY IMPROVEMENT TOOLS:

Criticality Analysis
What is Criticality Analysis?
Why do we need Criticality Analysis?
Criticality Assessment Benefits
How to Start?
Asset Criticality Ranking (ACR) Methodology
Reliability Centered Maintenance RCM
RCM Definition
RCM History and Standard
RCM Principles
RCM Process: The seven questions
Failure Mode definition and examples
Failure Mode and Effect Analysis (FMEA)
FMEA Process
FMEA Worksheet
Summary of RCM Process
RCM: Advantages and Disadvantages
The Scoreboard for Maintenance Excellence for RCM
PM Optimization, what is it and how to be implemented?
Root Cause Analysis
What is Root Cause Analysis?
Why do we need Root Cause Analysis?
RCA process
Key RCA tools and their application

DAY THREE

RELIABILITY AND MAINTENANCE JOURNEY TOWARDS EXCELLENCE

Defect Elimination
What is Defect Elimination? Why do we need it?
Steps to Defect Elimination
Precision Maintenance
Precession Maintenance Definition
The world of zero failure!
Precession Maintenance Fourteen Rules
Precision Maintenance Delivers Big Savings
Precision Brings Reliability to Assets
Typical Standards for a Precision Maintenance Program

MAIN ELEMENTS OF RELIABILITY ENGINEERING FOR MAINTENANCE

Reliability vs Maintenance Engineering
Reliability Tools
Reliability Engineering
Objectives of Reliability Engineering
Reliability Engineering Department Responsibilities
Effective Reliability Engineering
Reliability Analysis
Basic Measures of Reliability
Failure Rate
MTBF and MTTF
Mean Time Between Failure (MTBF)
Cost of Unreliability
Mean Time to Repair (MTTR)
Availability
Reliability Prediction
Sources of Reliability Data
Reliability Modeling
Example: Reliability Block Diagram (RBD)

DAY FOUR

MAINTENANCE ORGANIZATION OBJECTIVES AND CHALLENGES

Maintenance Organization
Maintenance Objectives
Maintenance Cost
Asset Lifecycle Cost
When Operating Costs are Committed
Maintenance Budget: Identifying the Main types of Maintenance Cost
Maintenance KPI: Maintenance proportion of the unit cost
Direct and Indirect Maintenance Cost
Case Study: Repair Time & Cost of a Centrifugal Pump Failure

MAINTENANCE PLANNING AND SCHEDULING IS THE KEY TO MAINTENANCE EXCELLENCE AND COST OPTIMIZATION

Planning Definition
Maintenance Planning and Scheduling is the Key to Maintenance Excellence
Difference between Planning and Scheduling
Scheduling Definition
What is scheduling about?
Maintenance Planning and Scheduling Function
Main Objectives of Maintenance Planning & Scheduling
Why Maintenance Planning?
Planning and Scheduling Efficiency
“World class” Wrench Time and Wrench Time Calculator
Planning, Scheduling & Coordination Benefits
Maintenance Planning and Scheduling Process
The Six Maintenance Planning Principles
Role of the Maintenance Planner
Maintenance Scheduling Principles
Scheduling Process
Role of the Maintenance Scheduler
Necessary Elements for Planning & Scheduling
Planning System Necessities
Planning is a Process and Needs Control
5 Ways to Measure Your Planning and Scheduling Maturity Matrix
The Scoreboard for Maintenance Excellence for Shop-level Reliable Planning, Estimating and Scheduling

DAY FIVE

COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS) AS A MAIN TOOL FOR MAINTENANCE PLANNING AND SCHEDULING AND WORK MANAGEMENT

What’s CMMS?
CMMS Objectives and benefits
CMMS main modules and functions
CMMS Failure Codes and their Importance for Failure Analysis
Work Management
Backlog Management
Standardized Maintenance Work Management Process
Step-1 Work Identification and prioritization
Step-2 Work Planning
Step-3 Work Scheduling
Step-4 Work Execution
Step-5 Completing the Work
Step-6 Review and Improve

SPARE PARTS MANAGEMENT

Spare Parts Management and Optimization
MRO Spares Management
Planning, Scheduling and Materials Management
Spare parts procurement process
Basics of inventory management

MANAGE USING KEY PERFORMANCE INDICATORS (KPI’S) AND BENCHMARKING

Key Performance Indicators (KPIs)
KPIs definition and Objectives
Leading and Lagging KPIs
Types of Planning and Maintenance Key Performance Indicators (KPI)
Examples of Important Key Performance Indicators (KPIs)
Benchmarking against the Industry Best Practices
What is Benchmarking?
What are the objectives of Benchmarking?
Examples of world-class benchmarks
Benchmarking against the Industry Best

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