Maintenance management best practices indonesia outline.compressed

Maintenance Management
Best Practices
(tools and techniques)

Best Practices (tools and techniques)
2
Trainer Bio:
Eng. Tom’s vast knowledge
of Electrical, Instrumenta-
tion, Maintenance, Planning,
Scheduling, Start-Up and
Commissioning (CSU), Root
Cause Analysis (RCA), Reliability
Centered Maintenance (RCM)
experience came from over 55
years of practical knowledge in
various sectors including Oil/
Gas, Petrochemical, Electrical
Utilities, Mining Military, Pulp/
Paper, Marine Electronics,
Agriculture and Maintenance
Reliability. This experience al-
lows Tom to provide extensive
formal presentation and train-
ing seminars covering all of the
above in both classroom and
Asset Management and Reli-
ability are technical, tactical
and strategic exercises that con-
sider human and organizational
requirements in order to ensure
sustainability. As a Senior Tech-
nical Advisor Tom champions
that the approaches are total,
sustainable and practical.

3
Course Description:
This course prepares students to fully
understand the system, tools and
techniques of maintenance man-
agement and the impact on opera-
tions. They will be able to assess the
potential of these techniques at the
background of their organization and
to devise a process to introduce the
methods and tools into the working
environment. During the lectures, the
instructor will present the key prin-
ciples in each of the key areas
Maintenance Management is an on-
going process which determines the
optimum mix of Reactive, Preventive,
Predictive, and Proactive mainte-
nance practices in order to provide
the required reliability at the mini-
mum cost.
These maintenance strategies, rather
than being applied independently,
are integrated to take advantage of
their respective strengths in order to
optimize facility and equipment oper-
constraints. The strategies include:
Reliability Centered Maintenance
(RCM), Root Cause Analysis, (RCA) and
Failure Mode Effect Analysis (FMEA).

4
Training Methodology:
The following course will
employ a time tested learning
methodology that is founded
-
ogy approaches:
Inquiry-Based Learning:1.
Asking challenging ques-
tions to get participants
intrinsically motivated
Problem-Based Learning:2.
Posing problems in differ-
ent stages of development
when variables are not con-
stant to ensure participants
understand and compre-
hend, not rote-respond.
Discovery-Learning: Setting3.
situations through case
studies, online tools, and
group discussion that allow
participants to come to
their own conclusions.
Co-operative Learning:4.
Having participants en-
gage together in complex
challenging problems and
collaboratively working
towards determining the
appropriate answer.

5
Authentic Learning: Focusing5.
on real-world examples with
complex problems and solu-
tions through exploring various
learning mediums including:
case studies, group activities,
online tools, and video pro-
gramming.
Using this balanced approach
to learning, Eng Tom Lloyd l will
ensure that the key learning objec-
tives of the program are empha-
sized and a seamless transfer of
knowledge takes place.
The following is a breakdown of
the blended learning tools that will
course:
40 % Lectures
30 % In-Class exercise works
and Practical Sessions
10 % Field Case Studies
20% Video

6
Who should attend:
Maintenance, Process and Production engineers
Technical supervisors
Operations personnel
Maintenance personnel
Planning and scheduling personnel
Entry level engineers
Course Objectives:
To provide a better understanding of:
The principles and functions of a maintenance
management
The basic types of maintenance (corrective, preven-
tive, predictive), their derivatives and combinations
risks
How to interface with operations and technical
teams
The total productive maintenance concepts, inte-
grated teams
Maintenance planning and scheduling including
shut down fundamentals
The types, structures and philosophies for selecting
Budget planning and cost controlling in mainte-
nance
Maintenance logistics, spare parts optimization
The role of HSE management

7
Course Agenda
Day 1
Day 2
Registration and Introductions
Introduction to Maintenance Management
Work Control and Effective Maintenance Strategies
Break
Data Collection and Analysis
Lunch
Course Pre-Test
Introduction to RCM
Break
Activity
Principles and Concepts of RCA
5 Whys Analysis
Break
5 Why case study
Maintenance Organization (purpose and function)
Lunch
Operations Organization (purpose and function)
O & M integration
Break
Reliability versus Continuous Improvement
Asset Maintenance programs
09:00 – 09:30
09:30 – 10:00
10:00 – 10:30
10:30 – 10:45
10:45 – 12:30
12:30 – 13:30
13:30 – 14:00
14:00 – 14:30
14:30 – 15:30
15:30 – 15:45
15:45 – 17:00
09:00 – 10:00
10:00 – 10:30
10:30 – 10:45
10:45 – 11:15
11:15 – 12:30
12:30 – 13:30
13:30 – 14:00
14:00 – 15:30
15:30 – 15:45
15:45 – 16:30
16:30 – 17:00

8
Day 3
Day 4
Principles and Concepts of FMEA
Activity; Perform FMEA for the example of your choice
Break
Maintenance Strategies
Understanding Risk Based Maintenance
Lunch
Risk, Reliability and Availability
Asset Management and Life Cycle Cost Control Concepts
Break
Equipment Condition Monitoring (vibration, temperature,
tribology)
Planning, Scheduling and Shut Down Management
Break
Maintenance Cost Control
Budget Planning
Activity:
Lunch
Annual Maintenance Plan
Maintenance Improvement Options
Identifying and Controlling Risk
Break
Understanding the Requirements of Material, Spare
Parts and Resources
09:00 – 10:00
10:00 – 10:30
10:30 – 10:45
10:45 – 11:15
11:15 – 12:30
12:30 – 13:30
13:30 – 14:00
14:00 – 15:30
15:30 – 15:45
15:45 – 17:00
09:00 – 10:30
10:30 – 10:45
10:45 – 11:30
11:30 – 12:00
12:00 – 12:30
12:30 – 13:30
13:30 – 14:00
14:00 – 15:00
15:00 – 15:30
15:30 – 15:45
15:45 – 17:00

9
Acronyms:
RCM – Reliability Centered Maintenance
RCA – Root Cause Analysis
O & M – Operations & Maintenance
FMEA – Failure Mode Effect Analysis
WO – Work Order
CMMS – Computerized Maintenance Management System
Day 5
Material Management in Maintenance
Work Control
Break
The Work Order (WO) process using CMMS
Lunch
Cost Control Objectives
The 13 Week Look-Ahead Process
Break
How to implement a Work Control Schedule
Course Post-Test and Feedback
09:00 – 10:00
10:00 – 10:30
10:30 – 10:45
10:45 – 12:30
12:30 – 13:30
13:30 – 14:30
14:30 – 15:30
15:30 – 15:45
15:45 – 16:30
16:30 – 17:00

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