Excellence in Reliability, Availability and Maintainability (RAM)

Introduction

Achieving excellence in maintenance and reliability is the aim of every organization that depends on its physical assets to achieve business objectives. Lower profit margins have made reducing maintenance costs imperative to the survival of many organizations. The overall cost of asset ownership is closely tied to the outcomes of reliability, durability, and longevity of physical assets. This training course is about developing and implementing the strategy and tactics that deliver the outcomes we need.

This Excellence in Maintenance and Reliability Management training course starts with the key aspects that lay the foundations and cornerstones of an effective maintenance function. It introduces reliability strategies such as FMECA, TPM, RCM and RCFA to highlight their costs and benefits. The Excellence in Maintenance and Reliability Management training course will then demonstrate how these strategies are used to derive the different maintenance tactics of predictive, preventive, detective and repair-after-failure maintenance tactics.

An in-depth analysis of risk-based processes such as Reliability-Centered Maintenance, the principles of Risked Based Maintenance and Totally Productive Maintenance; as well as a unique, practical application of the methodologies to demonstrate how they can be applied in the real world; are integral components of this training course.

Participants will develop the following competencies:

• Asset Functional Analysis
• Failure of Forecasting Risk Assessment
• Maintenance Strategy and Tactics Development
• Root Cause of Failure Analysis
• Reliability Improvement Project Facilitation

Objectives

The maintenance process has moved forward enormously in recent years, it is often difficult for maintainers and managers to keep abreast of the latest thinking and techniques. This seminar bridges that gap and presents recent, but proven, developments in a practical way enabling dele gates to transform maintenance from a cost item to a profit center.

There is a growing realization that maintenance management actually means managing risk. Upon completion of this course, delegates will acquire a practical knowledge and understanding of RCM (Reliability Centered Maintenance), TPM (Total Productive Maintenance) and continuous improvement (CI) Processes. Application of the method described in this course will produce a positive impact on business goals, for example:-

• Maintenance and improve uptime,
• Maximize safety,
• Achieve cost effective maintenance, and,
• Develop world class maintenance performance.

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in functions management. The pace and level of the training workshop is customized to the understanding of the delegates. Ongoing back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “competency transfer

Who Should Attend?

Maintenance managers and supervisors, asset managers, maintenance & engineering consultants, project manager and those involved in maintenance and operation in consultant, contractor or operating companies. The course has also been specifically designed to substantial benefit to both technical and non-technical personnel employed in the activities that supports the O&M sector

Course Outline

DAY1: Overview of RCM

• Maintenance in context (includes video presentation)
• Why RCM is Different
• RCM Fundamentals; The Term, The Process (includes delegate exercise )
• What should you expect from RCM
• Who should do RCM
• Selecting systems for RCM Analysis; Structured decision process

DAY 2: Reliability and maintainability

• Understanding Reliability (includes delegate exercise )
• Putting the reliability into RCM (Includes video presentation)
• How to use reliability information for maintenance
• Maintainability (includes video presentation )

Failure and failures modes

• Hidden evident failures (includes delegates exercise )
• Failure mode & effects, analysis, FMEA, & FMECA, (Include video presentation)
• Causes of failure

DAY 3: Total Productive maintenance

• Overview of TPM tools and Techniques
• How to position TPM within current improvement initiatives
• Organizational Changes involved to develop multifunctional teams
• The benefits from TPM and how to hold onto them 

DAY 4: TPM (cont)

• Overall Equipment Effectiveness (OEE)
  • Measurements Accuracy Reasons Why
  • How To Turn OEE Data Into Information

Continuous Improvement

• An overview of the C.I. Process
• How To Obtain Buy-in to the process from management
•  Tools and techniques

Day 5: Continuous Improvement (cont)

• KPIs (Key Performance Indicators)
  • What is critical?
  • Can we affect it?
  • How do we measure it?
  •  Action plan template for implementation

Work Planning, Scheduling and Work Control (Includes delegate exercise)

Functionality and Integration required from the CMMS

• Using CMMS history Analysis To Improve Reliability

Maintenance Administration 

• Organizational Structure Influence

Leadership Role