ICTD International Centre for Training and Development

Maintenance & Reliability Best Practices: Lowering Life Cycle Cost Equipment

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About the course

Maintenance and Reliability Best Practices are critical for every successful individual and company. This course introduces a lot of practical and new Maintenance and Reliability Best Practices concepts, techniques and tools. The costs associated with equipment downtime and reduced production can be significant. Learning how to effectively manage all aspects of your industrial facility is a must. This course provides best in class applications relating to maintenance planning and cost management strategies. It also will enable the candidates to better apply these tools and techniques in their organization.

Course Objectives

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

  • Apply the theory of this session using practical case studies.
  • Practice using improvement techniques
  • How to lower life cycle costs for equipment
  • How to have more reliable equipment
  • How to lower maintenance costs
  • Learn methods of better planning
  • Acquire improved team working between maintenance and production
  • How to have increased equipment performance
  • Learn strategies aligned to the business goals
  • Evaluate and justify your maintenance programs using Value: Benefit/ Cost.
  • Apply Life Cycle cost and risk planning to your facility assets.
  • Target Maintainability and/or Reliability in the development of your facility maintenance plans.
  • Learn the PLAN, DO, REVIEW cycle of continuous improvement.
  • Be introduced to the latest tools and techniques
  • Be exposed to best practices drawn from a range of different industries
  • Cover the required methodology to enable successful permanent changes
  • Be able to apply the most appropriate reliability improvement technique
  • Discuss the considerations of technical and human aspects of reliability improvement

Course Outline

Day 1

Asset Cost Management Introduction

  • Definitions of reliability, maintenance & asset management
  • The total cost of maintenance
  • Best practice reliability and maintenance processes
  • Elements of asset management best practice
  • Auditing performance
  • Overview of TPM, RCM, BCM, QCM, and other asset management buzzword
  • Open discussion sessions

Day 2

Laying the Groundwork

  • Team-work maintenance, operations, stores
  • The importance of standards such as PAS 55, JA1011
  • Corporate asset management expectations
  • Asset performance expectations
  • The forms of asset failure and degradation
  • The causes and nature of asset failure and degradation
  • The effects, cost and risks of asset degradation
  • Practical Application and Open Discussion sessions

Day 3

Applying the Value Based Process

  • Breaking the cycle of failure and degradation
  • Select PM tactics on the basis of costs and risks
  • How to determine PM intervals
  • Condition based maintenance types and the PF-curve
  • The four important reliability functions
  • Implementing best practice maintenance programs
  • Optimizing spares to support the maintenance program
  • Maintenance program cost and risk based justification
  • Practical Application and Open Discussion Sessions

Day 4

Ensuring the Continuity of the Value-based Process

  • Complete the PLAN, DO, REVIEW Improvement cycle with FRACAS
  • Failure Reporting, Analysis and Corrective Action System requirements
  • Structure and code data collection to support reliability analysis
  • How to quantify chronic failures and losses
  • Use Pareto analysis and stratification to focus the value-based analysis
  • Quantify losses in life cycle terms
  • Hypothesis root causes of failure and verify on the basis of evidence
  • Reliability Analysis Case Study
  • Discussion of software and templates to support analysis

Day 5

Supporting Process that Lower Life-cycle costs

  • Planning and scheduling best practice
  • Cost effective man-power and skills deployment
  • Performance indicators to drive continuous improvement
  • Overall review of concepts learned

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 maintenance engineers, reliability engineers, planners, maintenance supervisors, crafts and tradesmen, reliability technicians, operations supervisors, engineering and technical support staff including leadership and management and industry personnel.

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