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ICTD International Centre for Training and Development

Rules of Thumb for Maintenance and Reliability Engineers

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Description

Rules of Thumb for Maintenance and Reliability Engineers will give the engineer the “have to have” information. It will help instill knowledge on a daily basis, to do his or her job and to maintain and assure reliable equipment to help reduce costs. This course will teach engineers and managers needing immediate solutions to everyday problems.

Course Objectives

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

  • Apply the rules of thumb for maintenance and reliability engineers
  • Understand the basics of maintenance and reliability
  • Discuss the influence of functional maintenance, preventive and predictive maintenance program
  • Apply the reliability processes using the reliability software and understanding the KPI’s
  • Introduce total productive maintenance
  • Use the equipment and processes such as chain drives, chain selection, chain installation, chain length, chain speed and etc.
  • Determine the equipment used that includes hydraulics, maintenance welding, bearings, compressors, gears and gearboxes, etc
  • Discuss packing and seals and its methods as well as electric motors

Course Outline

Day 1

The Basics of Maintenance and Reliability: Understanding Maintenance and Reliability

  • The Maintenance Function
  • Strategy to Achieve World-Class Production through Reliability
  • What Is Reliability?
  • Maintenance/Reliability Assessment
  • Introduction to Change Management
  • Developing a Business Case for a Reliability Initiative
  • Calculating Return on Investment
  • Planning and Scheduling

The Functional Maintenance Organization and Its People

  • Functional Maintenance Organizational Structure
  • Maintenance Supervisor
  • Maintenance Planner/Scheduler
  • Responsibilities
  • Maintenance and Engineering Manager
  • Area Manager of Warehouse and Inventory Control
  • Reliability Engineer

Preventive Maintenance Program

  • Reliability-Based Preventive Maintenance
  • Identification of Functionally Significant Items
  • Maintenance Task Selection (Decision Logic Tree Analysis)
  • Maintenance Tasks
  • Task Frequencies/Intervals

Predictive Maintenance Program

  • Setting Up a Preventive/Predictive Maintenance Program
  • Visual Inspection
  • Vibration Analysis
  • Thermography
  • Tribology
  • Ultrasonic

Day 2

Reliability Processes

  • Reliability Software—Managing the Health of Assets
  • Seven Questions Addressed by Reliability Centered Maintenance
  • Failure Mode and Effects Analysis
  • Equipment Criticality Analysis
  • Root Cause Analysis

Key Performance Indicators

  • Defining and Understanding KPIs
  • The Problem
  • KPI Dashboards
  • Measuring and Managing the Maintenance Function

Total Productive Maintenance

  • Introduction to Total Productive Maintenance
  • Lean Reliability

Equipment and Processes: Chain Drives

  • Chain Selection
  • Chain Installation
  • Power Train Formulas
  • Chain Length
  • Multiple Sprockets
  • Chain Speed
  • Preventive Maintenance Procedures

Day 3

Hydraulics

  • Hydraulic Knowledge
  • Hydraulic Troubleshooter
  • General Maintenance Person
  • Best Maintenance Hydraulic Repair Practices
  • Root Cause Failure Analysis
  • Preventive Maintenance
  • Measuring Success
  • Recommended Maintenance Modifications

Maintenance Welding

  • Shielded Metal Arc Welding (SMAW), “Stick Welding”
  • Flux-Cored Arc Welding (FCAW)
  • Gas Tungsten Arc Welding (GTAW)
  • Applicability of GTAW
  • Advantages and Disadvantages of GTAW
  • Oxyacetylene Cutting
  • Air-Carbon Arc Cutting and Gouging
  • Applications
  • Power Sources
  • Plasma Arc Cutting
  • Welding Procedures
  • Qualification of Welders
  • Plasma Arc Welding
  • Base Metals
  • Control of Distortion
  • Special Applications
  • Selection and Maintenance of Equipment
  • Installation of Equipment
  • Equipment Operation and Maintenance
  • Safety

Day 4

Bearings

  • Types of Movement
  • Commonly Used Bearing Types
  • Bearing Materials
  • Lubrication
  • Installation and General Handling Precautions
  • Bearing Failures, Deficiencies, and Their Causes

Compressors

  • Centrifugal
  • Performance
  • Positive Displacement
  • Reciprocating
  • Troubleshooting

Gears and Gearboxes

  • Spur Gears
  • Pitch Diameter and Center Distance
  • Circular Pitch
  • Diametrical Pitch and Measurement
  • Pitch Calculations
  • Tooth Proportions
  • Backlash
  • Other Gear Types
  • Troubleshooting

Day 5

Packing and Seals

  • Fundamentals
  • Mechanical Seal Designs
  • Installation Procedures
  • Troubleshooting

Electric Motors

  • Bearing Frequencies
  • Imbalance
  • Line Frequency
  • Loose Rotor Bars
  • Running Speed
  • Slip Frequency
  • V-Belt Intermediate Drives
  • Electric Motor Analysis

Additional Readings on Maintenance and Reliability: Reliability Articles

  • Top Five Reasons Why Companies Don’t Measure Reliability: It Seems Like Everyone Has an Excuse as to Why They Don’t Measure Reliability
  • Creating a Culture Change in Your Maintenance Department: Is Your Maintenance Crew in a Reactive Mindset? Check Out a List of Qualifiers to Find Out and Then Learn How to Change It
  • Exterminate Lube Problems: Grease and Oil Expertise Can Be a Serious Competitive Edge
  • What It Takes to Make the Climb from Reactive to RCM
  • Put a Plant-wide Focus on Functional Failures
  • Reliability Is Worth a Second Look: Statistical Analysis and Time-Based Preventive Maintenance Don’t Really Address the Ability to Perform—It’s Time to Get Familiar with the Definition of Reliability
  • When Preventive Maintenance Doesn’t Work
  • The Top Four Reasons Why Predictive Maintenance Fails and “What to Do about It”

MTBF Users Guide

  • Understanding Definitions
  • The MTBF Process
  • Example

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 civil engineers, mechanical engineers, electrical engineers and to those who are facing issues relating to maintenance and reliability.

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