Maintenance and Reliability Master class

An introduction to the Model of Excellence

• How maintenance has evolved
• Sources of best practice and benchmarking options
• The pitfalls of traditional maintenance practices
• Understanding where money should be invested and where money tends to be wasted
• The importance of planning
• The relationship between fixed costs and maintenance performance
• A change in thinking
• Away from cost reduction or reliability or safety
• Towards cost reduction and reliability and safety
• The modern maintenance strategy and asset management
• How pace setters add value through maintenance innovation and integration with operating teams

Aligning Maintenance with the Business plan and Managing for Performance

• How to align maintenance with the unique requirements of any business
• Developing a maintenance vision and a credible plan for delivering this
• Launching and managing the Maintenance Improvement plan
• Selecting and tracking Key Performance Indicators to track progress towards the vision
• An overview of change management
• Overcoming resistance
• Processes and tools for managing change
• Effective management of Human Factors
• Identifying and satisfying stakeholders
• Communication
• Health, safety and environmental considerations

A Holistic Approach to Asset Reliability Improvement 

• Understanding the relevant management processes for any asset and operation
• Reliability Centred Maintenance
• Lean and six-sigma
• Total Productive Maintenance
• The ideal reliability road map
• Improving process performance
• Cost, risk and value engineering
• The principles of cost-effective maintenance investment
• Management processes
• Reliability improvement methodologies
• Change Management for key processes
• Auditing and assurance processes for compliance with reliability processes
• Conforming with local legislation and relevant standards

Improving Reliability at Equipment Level 

• Setting reliability targets at equipment level
• Assessing and baselining present equipment performance
• Analysis options to understand the underlying causes of inadequate equipment performance
• Root Cause Failure Analysis
• Weibull analysis
• Criticality analysis
• Failure Mode Effects and Criticality Analysis
• Development of effective maintenance plans
• Reactive
• Preventive
• Predictive
• Proactive
• Condition monitoring options for different equipment and failure modes
• A process to ensure new equipment reliability is at the required level
• Implementation of reliability plans for all equipment

Developing a High-Performance Team 

• Developing an organization that will support the reliability and maintenance strategies
• Setting a reliability focused culture
• The roles of personnel outside maintenance in reliability improvement and how to engage the right people in the right way
• Assessing gaps in the organization skills and the current capability vs that required
• Competency management (training and developing personnel).
• Leadership skills required to deliver full organizational performance
• Setting a reliability focused culture
• The roles of personnel outside maintenance in reliability improvement and how to engage the right people in the right way

Work Management (The Maintenance Process)

• Optimizing the workflow process and CMMS system performance
• Modern workflow management processes
• Adjusting efforts to drive performance and Continuous Improvement
• Identifying the correct scope of work
• The work that is critical
• Eliminating waste
• Approval and prioritization of work
• Planning and work pack development for maximum efficiency
• Scheduling work to meet targets and match resource plans
• On Time In Full work execution
• Tool time improvements
• Controlling HSE
• Recording work done, learning and improving future work

Work Management (Major Activities and Supporting Services)

• Planning and executing projects
• Managing maintenance materials and stores
• Use of computer-based technology
• An introduction to major maintenance tasks, shutdowns and turnarounds