ICTD International Centre for Training and Development

Achieving World Class Maintenance Performance

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About the course

Recent competitive trends have been pushing manufacturing executives to reconsider the impact and importance of increasing equipment availability and utilization, increasing maintenance productivity and resource utilization, and increasing quality and responsiveness of maintenance services in achieving World Class Status to meet world competition. Our comprehensive "World Class Maintenance" course will show you how to initiate and sustain a process of maintenance performance improvement, a process in which maintenance is recognized as critical to the overall production strategy by which your plant provides the product to the customer at a quality he wants and a price they are willing to pay.   This comprehensive course will open your eyes to World Class Maintenance practices and show you how to initiate and sustain a process of maintenance performance improvement in today’s market. Discover how your facility measures up to world class companies by reviewing benchmark data and evaluating maintenance best practices.   You will gain an understanding of the key areas for maintenance effectiveness and efficiency such as work management systems, planning and scheduling, preventive/predictive maintenance, inventory control. Learn how to successfully engage production with key maintenance and reliability initiatives for maximum results.    

Course Objectives

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

  • Evaluate their plant's maintenance practices and develop a program to achieve "world class" maintenance performance
  • Understand how their plant's maintenance practices compare with industry leaders In addition, they will be able to identify key improvement areas and understand the steps that are required to achieve the desired savings
  • Understand the practices used by industry leaders to achieve successful T/As. They will learn the seven phases of T/A management and the actions necessary in each phase
  • Conduct work request justification reviews, which are based on the business principle of return on maintenance investment. They will have an understanding of how to develop risk scenarios reflecting realistic consequences and probabilities that can be used to establish the needed scope and timing of maintenance work
  • Understand the principles of Life Cycle Maintenance Management (LCMM). Finally, participants will have an understanding of how to develop LCMM plans for their key equipment and the application of this information to the development of maintenance budget  

    Course Outline

      ### Day 1   Maintenance Practices That Improve Plant Profits   This introduces the concepts of benchmarking maintenance performance against industry leaders. It focuses on changing maintenance philosophy and outlines top performer practices. A stepwise approach to improving maintenance performance is presented. The following topics are covered:

  • Strategy for Maintenance Excellence

  • Symptoms of Poor Performance

  • Competitive Performance

  • Changing Maintenance Philosophy

  • Top Performer Practices

  • Achieving Progress   ### Day 2   Turnaround (T/A) Management   This introduces the concepts associated with the successful planning and execution of major T/As. It presents milestones identifying the actions needed and their appropriate timing. The following topics are covered:

  • Strategic Planning

  • Scope Control

  • Budget Development and Control

  • Detailed Planning

  • Contracting

  • Execution

  • Close-Out Assessment   ### Day 3   Work Request Justification   This introduces the concept of risk-based work justification. It presents the methodology for justifying the need, scope, and timing of maintenance work. The following topics are covered:

  • Organizational Roles

  • Required vs. Discretionary"

  • Risk-Based Decision-Making

  • Priority Setting

  • Justifying Work Scope

  • Savings/Cost Analysis

  • Time Value of Money   ### Day 4   Life Cycle Maintenance Management   This introduces the concept behind Life Cycle Maintenance Management (LCMM). It presents a stepwise approach to develop LCMM Plans based on top performer practices. The following topics are covered:

    • Define Areas of Vulnerability
    • Identify Critical Components
    • Timing and Consequence Assessment     ### Day 5   Life Cycle Maintenance Management (cont’d)
    • Assess Timing and Scope of Maintenance Intervention
    • LCMM for Spared Equipment
    • Managing LCMM Data   ## 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

Who should attend

This course is intended for supervisors and managers who are assigned in maintenance cost, equipment, and unit reliability responsibilities. Participants should have an understanding of their plant's current performance, maintenance practices, and opportunities for improvement. Individuals responsible for T/A cost and unit performance will also benefit from this course. Participants should have an understanding of their current T/A practices.

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