The programme

Innovative strategies is the core to our agenda’s structure. The conference offers discussion-based sessions focused on putting our delegates at the centre of the conversation

  • 09:00 AM
    Registration and networking
  • Module 1
    Risk Based Asset Management
    1. Review of corporate values and organizational culture.
    2. The 80/20 or Pareto Rule, 80% of production downtime costs come from 20% of installed equipment.
    3. Managing the critical 20% is the fastest and most efficient way to increase reliability inc
    4. Determining the 20% using an FMECA.
    5. Using strategic maintenance plans to manage the critical 20%.
    6. Risk -Based Maintenance Management - RCM and ISO 55000
  • 10:30 AM
    Coffee Break
  • Module 2
    Industrial Reliability Centred Maintenance
    1. History of RCM and RCM2
    2. The SAE Standard
    3. Definition of i-RCM evolution
    4. RCM is a business strategy
    5. RCM is a scientific process
    6. Process based management
    7. RCM Research
    8. 80/20 Rule
    9. Why we do an FMECA
    10. Understanding failures
    11. Human error
    12. Collateral damage
    13. PF- Interval vs what really works!
    14. Fire Fighting – The vicious Loop
    15. Real costs of downtime
    16. Benefits of RCM
    17. Growth under RCM
  • 01:00 PM
    Lunch
  • Module 3
    Maintenance General Best Practices
    1. Why we need best Practices
      • To reduce human errors that affect reliability
    2. Using Technology and Techniques to reduce Error
    3. Types of human error
    4. Best practices programmes generally Include:
      • Error-proofing (tagging , color-coding, mechanical preventions etc.
      • Procedures or step by step processes to follow
      • Improving documentation
      • Improving training
      • Improving management
      • Auditability
    5. Examples of Maintenance Best Practices
      • Predictive Maintenance Practices
      • Lubrication organization and labelling practices
      • Lubricant clean storage and dispensing practices
      • Bearing lubrication practices
      • Precision dial or laser alignment techniques
      • Precision mechanical practices
      • Electric motor storage practices
      • Motor circuit analysis
      • Effective work scheduling PMs, PdMs, Critical Work
      • Procedural documentation – PM Work Orders
      • Critical work specifications (SOPs)
      • Benchmarking
      • Training
  • 03:30 PM
    Coffee Break
  • Module 4
    General Business Concepts
    1. Organizational foundations and structures, organizational leadership
    2. Common strategic planning and analysis techniques
      • Gap analysis, SWOT Analysis, Root Cause Analysis
      • Balanced Score carding
    3. Employee evaluation practices
    4. Definition Of organizational culture change
  • 05:00 PM
    End of Day 1
  • 09:00 AM
    Registration and networking
  • Module 5
    Best Practices for Planning and Scheduling
    1. Planned and scheduled work is 4-6 times less expensive than unplanned unscheduled work
    2. Planned work is more precisely executed and Higher Quality
    3. Developing an EMP (Equipment Maintenance Plan)
    4. Planned work Includes:
      • PdM’s driven work (repairing early detected failures)
      • PMs
      • Inspections
      • Rebuilds
      • Replacements
      • New installations
      • Project or construction work
  • 10:30 AM
    Coffee Break
  • Module 5
    Best Practices for Planning and Scheduling
    1. Planning functions Include:
      • Parts and materials availability
      • Parts kitting for specific tasks
      • Special tools or equipment availability
      • Required safety permits (confined space etc)
      • Skilled personnel availability
      • Proper work documentation
      • Contacting third-party services
    2. Scheduling functions include
      • Interfacing with operations for all planned work.
      • Prioritizing Work
        • PdM - Critical Work
        • Critical PM’s
        • Rebuilds retrofits
        • Regular PM’s
        • Inspections
        • Projects & construction work .
      • Contingency planning
      • Reallocation of resources
      • Tracking PM backlogs
      • Management notification of critical work backlogs
      • Scheduling third party services
  • Module 6
    Understanding Systems Analysis - The FMECA Process
    1. FMEA vs FMECA
    2. FMEA is for design! Not RCM!
    3. Steps for performing an FMECA
      • Develop a systems ID code method
      • Identify systems and sub-systems by
      • Creating a system process flow diagram
      • Compile clear function statements for systems
      • Define equipment and component functional failure modes
      • Assign & audit appropriate risk factors
      • Enter the data into the FMECA database or spreadsheet
      • Compile the results as a strategic roadmap!
  • 01:00 PM
    Lunch
  • Module 6
    Understanding Systems Analysis - The FMECA Process
    1. FMECA is a SYSTEMS ANALYSIS and is only concerned with functional failures!
    2. Making Systems Function Statements
    3. Looking at Function Loss and system consequences
    4. Functional Failure Mode Mapping
    5. Risk Analysis scoring is based on the impacts that a functional failure has on the systems function statement.
    6. Every functional failure mode must be risk analyzed
    7. Operational criticality scoring
    8. Safety and environmental criticality scoring
    9. What you know and do not know after a FMECA
  • Module 7
    Strategic Maintenance Planning
    1. Part failure modes analysis
      • Past parts failures
      • Common parts failures
    2. PdM technology selection
      • Ultrasonic baselines
      • Vibration
      • Oil-Analysis
      • Thermography
      • MCA / MSA (Electric Motors)
      • NDT – Static
      • Corrosion Trending - Static
    3. PdM Frequency
      • Consider collateral damage too not just PF interval!
    4. Critical work specifications
      • Think reliability not just Repair
      • What can we do to head off the next failure?
      • Sectional rebuilds etc.
    5. Critical Inventory
      • Critical parts kitting
      • Special considerations
      • Training
      • Other factors
  • 03:30 PM
    Coffee Break
  • Module 7
    Strategic Maintenance Planning
    1. Re-commissioning specification or work completion specs
      • You say you fixed it – prove it!
    2. Process SOPs for reliability
    3. Strategic shutdown and turnaround procedures should Include.
      • Scope of work
      • Detailed documentation of work
      • Working hours required
      • Special tools required
      • Parts required
      • Special skills or personnel required Local and OEM
      • Permits required
      • Re-commissioning specs
      • Production readiness certification process
      • Identified SMEs local and OEM
  • 05:00 PM
    End of Day 2
  • 09:00 AM
    Registration and networking
  • Module 8
    Best Practices for Planning and Scheduling
    1. Areas of Inventory Best Practices
      • Safety
      • Daily visual inspections
      • Spare parts integrity
      • Corrosion control practices
      • Cleanliness control
      • Packaging integrity
  • 10:30 AM
    Coffee Break
  • Module 8
    Inventory Best Practices
    1. Critical Spares vs Regular Inventory
      • Critical spares inventory must be managed in a different way than normal spares inventory.
      • Maintaining part integrity is mission critical
      • Facility environmental requirements are more strict.
      • Rules for accepting and returning parts to Inventory are strict.
      • Re-order specifications can vary greatly between parts.
      • Personnel handling critical spares require training!
      • Confidence in spares availability is critical
      • Training requirements for critical spares management
  • Module 9
    Maintenance Management - Justifying Staffing Levels
    1. Why we need to justify staffing
    2. Ways to measure staffing levels
    3. Developing good internal metrics
    4. General KPI metrics for staffing analysis
    5. Craft Backlog
    6. 4-6 weeks
    7. Most Operations are actually overstaffed
      • Why?
        • Excessively Reactive
        • No proactive work
        • Firefighting etc.
  • 01:00 PM
    Lunch
  • Module 10
    Managing People
    1. Team Building
      • Forming
      • Storming
      • Norming
      • Performing
    2. Maslow’s Needs
      • Motivations
    3. Designing training programmes
    4. Employee Evaluations
      • Employee goal-setting
    5. Team leadership
    6. Team facilitation
  • Module 11
    Plant Process Reliability
    1. Process based management
    2. Capacity factor
    3. Failure rate - 1/MTBF
    4. OEE
    5. Reliability numbers
    6. TEEP
    7. Reliability engineers job description
      • Loss elimination, risk management, life cycle management (LCAM)
  • 02:45 PM
    Coffee Break
  • CRCMP Exam
    Duration: 2.5 Hours

    Type of questions: Multiple-choice
    No. of Questions: 110

  • 05:30 PM
    End of Day 3