MAINTENANCE PLANNING EXCELLENCE – THE BEST STRATEGIES FOR PLANNING AND SCHEDULING

About the Event

Learn how to radically improve plant performance and essentially reduce maintenance costs via advanced maintenance planning and scheduling

Top 4 Benefits of Attending

  1. Protect and enhance values of your plant machinery with the advanced maintenance planning and scheduling best practices principles
  2. Understand roles and duties of a maintenance planner and scheduler and creation of high quality work orders
  3. Discover how to effectively integrate reliability centered maintenance with maintenance planning and scheduling for achieving maximum machinery uptime and essential reduction of maintenance costs
  4. Learn practical implementation of advanced maintenance planning and scheduling principles, Computerized Maintenance Management Systems (CMMS) and Enterprise Resource Planning Software

Who Should Attend?

This highly interactive training course will benefit anyone responsible for maintenance, who wishes to build competency in maintenance planning and scheduling to improve plant performance. This includes plant directors, senior plant managers, maintenance supervisors/coordinators, operation managers and supervisors and materials and storeroom managers who are involved in plant maintenance and reliability and equipment availability.

Course Introduction

Maintenance planning and scheduling using structured and systematic approaches are critical for every successful plant. Maintenance planning and scheduling are the fastest and most effective investments that an organization can make to improve plant productivity and equipment availability.

This course is designed to build competency in maintenance planning and scheduling. The techniques that participants will learn in this course will allow for effective planning and scheduling of maintenance resources. The course covers all the fundamentals and advanced methods and applications that a suitably qualified professional would use in carrying out fully functional plant maintenance. In summary, the course provides a step-by-step practical guide to best practices of maintenance planning and scheduling that will essentially reduce maintenance costs and deliver maximum business benefits.

This training course is based on 35 years of real-life industrial experience of the trainer in maintenance planning and scheduling.

Course Outline

  • The course will start with systematic and structured analysis of the main maintenance best practice planning and scheduling principles.
  • Analysis of potential and functional machinery failures, hidden and evident failures, failure modes, effects and consequences will be undertaken that play essential role in maintenance type estimation.
  • Optimal planning of preventive/predictive maintenance will be discussed in details.
  • The advanced techniques: failure mode and effect analysis (FMEA) and failure mode, effect and criticality analysis (FMECA) for maintenance planning will be discussed in details.
  • The effective field-proven condition monitoring technologies (i.e. vibration, acoustic emission, infrared thermography and wear debris) that should be used for work order development will be described in detail.
  • Integration of reliability centered maintenance/risk based maintenance with maintenance planning and scheduling will be discussed in detail.
  • Finally, Computerized Maintenance Management Systems (CMMS) and radically novel Enterprise Resource Planning Software will be demonstrated.

Course Format

The course will be presented in an interactive format with ample details from the trainer. The trainer will use comprehensive Power Point slides, hand-outs and industrial case study material, including videos and practical Group exercises.

The Main Course Objectives Include:

  • Systematic and structured analysis of the main maintenance best practice planning principles
  • Systematic and structured analysis of the main maintenance scheduling principles and best practices
  • Optimal planning of preventive and predictive maintenance
  • Failure mode and effect analysis (FMEA) and failure mode, effect and criticality analysis (FMECA) for maintenance planning
  • Effective use of field-proven condition monitoring technologies (i.e. vibration, acoustic emission, infrared thermography and wear debris) for maintenance work orders
  • Integration of reliability centered maintenance with maintenance planning and scheduling
  • Maintenance planning for shutdowns
  • Management of maintenance backlog
  • Demonstration of Computerized Maintenance Management Systems (CMMS) and radically novel Enterprise Resource Planning Software
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Session One

Ensuring that your Maintenance Planning and Scheduling Contributes to the Company’s Profit to Achieve Business Outcomes

  • Introduction
  • Maintenance: Definitions, the Main Concepts and the Seven Basic Questions/Solutions
  • Build Systematic Maintenance Tactics for Your Organization:
  • Preventive/Time Based Maintenance
  • Predictive /Condition Based Maintenance
  • Run to Failure Maintenance
  • Proactive Maintenance
  • Maintenance by Redundancy
  • Opportunity Maintenance
  • Opportunistic Maintenance
  • Corrective Maintenance
  • Maintenance Budget: Identifying the Main Maintenance Costs
  • Classification of Day to Day Maintenance Jobs
  • Planning and Scheduling Maintenance: Introduction
  • Flow Chart of Maintenance Planning and Scheduling
  • Developing High Quality Maintenance Work Orders
  • Work Orders: Top Ten Essential Estimations
  • Work Orders: Industrial Case Studies
  • Planning and Scheduling Maintenance: Who Are the Main People? A Planner, a Maintenance Supervisor, a Craftsman, Storeroom Personnel, an Operations Superintendent and an Operator
  • Conceptualizing Planning and Scheduling as the Key Elements of the Maintenance Process:
  • The Main Maintenance Best Practice Planning Principles
  • The Main Maintenance Best Practice Scheduling Principles
  • Selecting and Deploying the Right Planner to Maximize Benefits of Planning Process
  • Maintenance Plan: the Main Rules
  • Effective Methods for Estimation of the Standard Job Hours for Work Orders
  • Estimation of the Standard Job Hours for Work Orders: Case Study
  • Why Week is Enough for Advanced Maintenance Schedule?
  • Wrench Time in Maintenance Planning

Session Two

Selecting Maintenance Types for Work Orders that Increases Reliability of Assets and Makes Cost-Effective Maintenance

  • Selecting Maintenance Types for Work Orders
  • Maintenance Strategy: Seven Stages Process
  • Asset Functions: Primary and Secondary
  • Asset Failures: Potential and Functional
  • The Instantaneous Hazard (Failure) Rates: Traditional View, Bathtub, Slow Aging, Best New, Random Failure and Worst New
  • Relationship Between the Failure Rate Pattern and Maintenance Type Selection for Work Orders
  • Planning Job Frequencies for Work Orders for Predictive Maintenance Using the P-F Interval and the Net P-F Interval
  • Estimation of the Optimum Maintenance Interval for Work Orders for Predictive and Preventive Maintenance
  • Estimation of the Optimum Maintenance Interval for Work Orders for Predictive and Preventive Maintenance: Industrial Case Studies
  • Asset Operating Context
  • Asset Operating Context: Industrial Case Studies
  • Failure Modes
  • Hidden and Evident Failures
  • Analyzing Failure Effects
  • Analyzing Asset Failure Consequences for Maintenance Type Selection:
  • Hidden Consequences
  • Safety and Environmental Consequences
  • Operational Consequences
  • Non-Operational Consequences
  • Determining Asset Criticality for Work Orders
  • The Key Maintenance Metrics:
  • the Mean Time Between Failures
  • the Failure Rate, the Instantaneous Failure Rate for Plant Machines/Equipment
  • Plant Machines/Equipment Availability and Maintainability
  • the Mean Time to Failure
  • the Mean Time to Repair
  • Reliability
  • Selecting Maintenance Types for Work Orders:
  • Predictive Maintenance
  • Preventive Maintenance
  • Failure Finding Maintenance
  • Maintenance by Re-Design/Redundancy
  • Breakdown Maintenance
  • Determining When to Prevent Failure and When to Allow Failure to Occur; Replace, Maintain or Refurbish: Optimally Planning Your Maintenance Actions
  • Logic Diagram for Maintenance Type Selection for Work Orders
  • The Comprehensive List of the Main Key Maintenance Performance Indicators

Session Three

Bridging the Gap between Asset Risks and Maintenance Planning to Ensure that Necessary Resources are Properly Allocated

  • Assessing Risks: Introduction
  • Hazard Analysis and Risk Analysis
  • Risk Based Maintenance: Estimating Asset Risks of Failure and Planning Maintenance Based on Risks
  • Fault Tree Analysis for Risk Based Maintenance Planning
  • Fault Tree Analysis: Industrial Case Studies
  • Event Tree Analysis for Risk Based Maintenance Planning
  • Event Tree Analysis: Industrial Case Studies
  • HAZOP (Hazard and Operability Study) for Risk Based Maintenance Planning
  • HAZOP: Industrial Case Studies
  • HAZOP: Group Exercise
  • Risk Based Maintenance: Industrial Case Study
  • Cost Benefit Analysis
  • Life Cycle Cost Technique for Creating Work Orders
  • Outsource Maintenance vs In-House Maintenance: What Works Best for Your Organisation
  • Spare Part Management and Outsourcing
  • ABC Analysis and XYZ Analysis in Spare Part Management
  • Operations vs. Maintenance
  • Importance of Maintenance Planning and Scheduling
  •  Failure Mode and Effect Analysis (FMEA) for Maintenance Planning
  • Review Design and Operation of Chosen Machine/Equipment
  • Review Failure History and Failure Modes
  • Review Root Causes of Failure Modes; Estimate Root Cause Occurrences
  • Review Failure Consequences; Estimate Severities of Consequences
  • Review Detection/Diagnosis Capabilities; Estimate Detection/Diagnosis Capabilities
  • Estimate the Risk Priority Numbers
  • Assign Optimized Maintenance Tasks/Frequencies
  • Failure Analysis Review
  • FMEA: Ranking
  • FMEA: Industrial Case Studies
  • FMEA: Group Exercise
  • Failure Mode Effect and Criticality Analysis (FMECA) for Maintenance Planning
  •  FMECA: Industrial Case Study

Session One

Best Practices of Planning and Scheduling During Plant Shutdowns and Overhauls

  • Five Phases of Plant Shutdown
  • When Shutdown Should Start? Shutdown Stages:
  • Pre-Shutdown Stage
  • Shutdown Stage
  • Post-Shutdown Stage
  • Effective Shutdown Preparation for Avoiding Unknown Defects and Maximizing

Shutdown Success

  • Pre-Shutdown Check List
  • Estimation of Shutdown Duration using Cost-Benefit Analysis
  • Critical Path Analysis for Estimation of Shutdown Duration
  • Long-Term Shutdown Planning; Completing the Shutdown Plan and Schedule
  • Management of Overhauls:
  • Time Between Overhauls
  • Service Limit Overhauls
  • New Limit Overhauls

 Session Two

Top Factors Ensuring that Shutdown Happens Efficiently, Without Essential Delays and Unexpected Costs and According to What Was Planned

  • Contractor Management System for Shutdowns
  • Shutdown: External Risks
  • Shutdown Work List
  • Determining True Shutdown Jobs
  • Shutdown Work Scope
  • Shutdown Job Planning and Scheduling
  • Focus on Overall Daily Work Completion
  • Shutdown Strategic Planning
  • Stress During Shutdown
  • Shutdown: Purchased Materials and Services
  • Key Performance Indicators for Plant Shutdown

Session Three

Planning Predictive Maintenance Using Condition Based Maintenance (CBM) Technologies

  • Innovative CBM Approaches to Maximize Equipment Availability
  • How to Plan Vibration CBM for Work Orders
  • How to Plan Acoustic Emission CBM for Work Orders
  • How to Plan Wear Debris CBM for Work Orders
  • How to Plan Infrared Thermography CBM for Work Orders
  • New International Standard for Planning Condition Based Maintenance for Work Orders
  • Condition Based Maintenance: Nine Industrial Case Studies, Including Four Video Case Studies

Session One

Improving Advanced Planning and Scheduling for your Management Process. Maintenance Software and the Main Planning/Scheduling Techniques

  • Computerized Maintenance Management System (CMMS):
  • Asset Records
  • Asset Control
  • Plant and Equipment Information
  • Work Order Issue and Control
  • Estimation of Maintenance Key Performance Indicators
  • Inventory/Stores Management
  • Planning Predictive/Preventive Maintenance
  • Managing Condition Monitoring Outputs
  • Advanced Maintenance Planning Software:
  • Equipment Selection
  • Failure/Fault Consequence Classification
  • Priority of Maintenance Tasks
  • Frequency for Predictive/Preventive Maintenance
  • Optimum Combination of Maintenance Tasks
  • Corrective Maintenance
  • Management of FMEA and FMECA
  • Maintenance Tasks: Reports and Graphical Presentation
  • Management of Maintenance Backlog

Session Two

Enterprise Resource Planning (ERP). Maximizing ERP as a Tool to Reduce Costs and Improve Productivity, Quality and Control

  •  Enterprise Resource Planning Software
  • ERP: the future trends

 Session Three

Planning Proactive Maintenance via Root Cause Analysis and Failure Assessment to Essentially Cut Unnecessary Maintenance Costs

  • Root Cause Analysis of Fault/Failures for Work Orders for the Proactive Maintenance; an Approach of Six Root Factors
  • The Generic “Eight Disciplines Problem Solving” Technique for Root Cause Analysis Planning for Work Orders
  • “5 Whys” Technique for Root Cause Analysis
  • Fishbone (Ishikawa) Diagram for Root Cause Analysis
  • Root Causes of Assets Failures: Description
  • Planning Industrial Root Cause Analysis for Work Orders: 17 Industrial Case Studies
  • Planning Failure Assessment for Work Orders: 9 Classical Steps
  • Planning Failure Assessment for Maintenance: Industrial Case Studies

Session Four

The People Matter: Developing Sustainable Planning by your Team to Meet Future Needs of the Proactive Maintenance

  • Implementation of the Proactive Maintenance: Teamwork and Facilitator
  • Human Errors in the Proactive Maintenance
  • Reduction of Human Errors in the Proactive Maintenance
  • Work Breakdown Structures: the Main Principles
  • Gantt Chart: the Main Principles
  • Time Planning for Maintenance
  • Planned Maintenance: Application and Achievements; Measuring Effectiveness of the Planning and Scheduling Process
  • Review: Learning Outcomes

Closing Comments

Prof. Len Gelman
TRAINER AND CONSULTANT
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Event Details
  • Days
    Hours
    Min
    Sec
  • Start Date
    November 22, 2021 09:00
  • End Date
    November 24, 2021 17:00
  • Status
    Upcoming
  • Location
  • Category
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