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
- Review of corporate values and organizational culture.
- The 80/20 or Pareto Rule, 80% of production downtime costs come from 20% of installed equipment.
- Managing the critical 20% is the fastest and most efficient way to increase reliability inc
- Determining the 20% using an FMECA.
- Using strategic maintenance plans to manage the critical 20%.
- Risk -Based Maintenance Management - RCM and ISO 55000
- History of RCM and RCM2
- The SAE Standard
- Definition of i-RCM evolution
- RCM is a business strategy
- RCM is a scientific process
- Process based management
- RCM Research
- 80/20 Rule
- Why we do an FMECA
- Understanding failures
- Human error
- Collateral damage
- PF- Interval vs what really works!
- Fire Fighting – The vicious Loop
- Real costs of downtime
- Benefits of RCM
- Growth under RCM
- Why we need best Practices
- To reduce human errors that affect reliability
- Using Technology and Techniques to reduce Error
- Types of human error
- 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
- 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)
- Organizational foundations and structures, organizational leadership
- Common strategic planning and analysis techniques
- Gap analysis, SWOT Analysis, Root Cause Analysis
- Balanced Score carding
- Employee evaluation practices
- Definition Of organizational culture change
- Planned and scheduled work is 4-6 times less expensive than unplanned unscheduled work
- Planned work is more precisely executed and Higher Quality
- Developing an EMP (Equipment Maintenance Plan)
- Planned work Includes:
- PdM’s driven work (repairing early detected failures)
- New installations
- Project or construction work
- 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
- Scheduling functions include
- Interfacing with operations for all planned work.
- Prioritizing Work
- PdM - Critical Work
- Critical PM’s
- Rebuilds retrofits
- Regular PM’s
- Projects & construction work .
- Contingency planning
- Reallocation of resources
- Tracking PM backlogs
- Management notification of critical work backlogs
- Scheduling third party services
- FMEA vs FMECA
- FMEA is for design! Not RCM!
- 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!
- FMECA is a SYSTEMS ANALYSIS and is only concerned with functional failures!
- Making Systems Function Statements
- Looking at Function Loss and system consequences
- Functional Failure Mode Mapping
- Risk Analysis scoring is based on the impacts that a functional failure has on the systems function statement.
- Every functional failure mode must be risk analyzed
- Operational criticality scoring
- Safety and environmental criticality scoring
- What you know and do not know after a FMECA
- Part failure modes analysis
- Past parts failures
- Common parts failures
- PdM technology selection
- Ultrasonic baselines
- MCA / MSA (Electric Motors)
- NDT – Static
- Corrosion Trending - Static
- PdM Frequency
- Consider collateral damage too not just PF interval!
- Critical work specifications
- Think reliability not just Repair
- What can we do to head off the next failure?
- Sectional rebuilds etc.
- Critical Inventory
- Critical parts kitting
- Special considerations
- Other factors
- Re-commissioning specification or work completion specs
- You say you fixed it – prove it!
- Process SOPs for reliability
- 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
- Areas of Inventory Best Practices
- Daily visual inspections
- Spare parts integrity
- Corrosion control practices
- Cleanliness control
- Packaging integrity
- 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
- Why we need to justify staffing
- Ways to measure staffing levels
- Developing good internal metrics
- General KPI metrics for staffing analysis
- Craft Backlog
- 4-6 weeks
- Most Operations are actually overstaffed
- Excessively Reactive
- No proactive work
- Firefighting etc.
- Team Building
- Maslow’s Needs
- Designing training programmes
- Employee Evaluations
- Employee goal-setting
- Team leadership
- Team facilitation
- Process based management
- Capacity factor
- Failure rate - 1/MTBF
- Reliability numbers
- Reliability engineers job description
- Loss elimination, risk management, life cycle management (LCAM)
Type of questions: Multiple-choice
No. of Questions: 110