Total Plant Reliability Centered Maintenance (RCM)

Introduction

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 course bridges that gap and presents recent, but proven, developments in a practical way enabling delegates 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 methods described in this course will produce a positive impact on business goals, for example:

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

This will be an interactive, enjoyable and interesting learning experience.  It will utilize a variety of methodologies including lectures and slide presentations.  The course is structured to give you an introduction to the RCM, TPM and CI processes with a thorough grounding in the key elements. It offers practical advice and guidance on their use, particularly as they are applied in industry.  Examples and group exercises allow delegates to acquire a more detailed and practical understanding.  Examples of actual obstacles encountered during RCM, TPM and CI studies will be highlighted. The participation of delegates will be encouraged throughout. Delegates will also have the opportunity to discuss issues relevant to their workplace if they so wish.

Objectives

Upon the successful completion of this course, each participant will be able to:-

• Apply and gain in-depth knowledge on the background of Total Plant, Reliability Centered Maintenance (RCM) including its history, terminology, objectives and critical success factors
• Recognize reliability and availability and determine the use of reliability information for maintenance
• Analyze the failure process and become familiar with FMEA, FMECA, failure consequences as well as the hidden & evident failures
• Enumerate the various maintenance tasks and emphasize the analytical decision logic for RCM
• Prepare a maintenance program using the guidelines & procedures and be able to discuss the important key points in developing the maintenance program
• Recognize the need for modification control and carry-out maintenance implementation strategies
• Demonstrate RCM audits and assessments and be able to identify the other tools used in RCM such as Failure Analysis and HAZOP studies
• Identify total productive maintenance (TPM) tools & techniques and determine the benefits from TPM towards having a world-class maintenance
• Recognize  the continuous improvement process as well as its tools & techniques and review the Key Performance Indicators (KPIs)
• List the support elements of RCM and use a system approach in work planning, scheduling and work control
• Identify the functionality and integration required from the CMMS and employ modern maintenance management

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This course is intended for maintenance managers, engineers, supervisors, and foremen, asset managers, maintenance & engineering consultants, project managers and those involved in maintenance and operations (M&O) in consultant, contractor or operating companies.  The course is also beneficial to both technical and non-technical personnel employed in the activities that support the O&M sector.

Course Outline

Day 1: Reliability Centered Maintenance

• Introduction of RCM
• RMA (Reliability, Maintenance and Availability) Concepts
• Functional Criticality Analysis
• RCM Stages and Tools – RCM, FMEA, FMECA, Road Map

Day 2:

• Total Productive Maintenance
• TPM Overview – Breaking down Barrier, Hidden Losses, Cultural Change, New Mindset
• TPM Initiation – Philosophy of Awareness, Improvement Program Study, Setting up Pilot Project
• TPM Planning – Agree & Assign Accountability, Design Zoning Policy, Critical Equipment Analysis
• TPM Action – Tagging, Cando Procedures and Standards, KPI, Develop Focus Project, Discipline Communication, Analytical Problem Solving, TPM Consolidation (Institutionalizing Practices, Personal Development Review).

Day 3:

• Business Process Re-Engineering
• BPR Overview – Functional Orientation, Losses, Methodology, Customer and Expectations.
• Customer Expectations – Types of Customer, Core customer, Typical Expectations, Establishing Expectations, Objectives Measures and Targets.
• ·Identifying Primary Process, Selecting Re-Engineering Projects, Mapping Activities.
• Business Process Re-Engineering – Re-Engineering Process, Relational Mapping, Characteristics, Re-Engineering Principles,  Issues, Process Assumptions and Constraints and testing.

Day 4:

• Applications & Implementation
• Continuous Improvement,
• Closed-Loop Control,
• Targets and trending,
• Problem Solving,
• Implementation,
• Integrated Team,
• Project Management,
• Key Success Factor.

Day 5: Engineering

Getting Started – Assessment of Improvement potential,

• Benchmarking,
• Plant Downtime Analysis,
• Chronic and Acute Failures,
• Overall Equipment Effectiveness,
• Statistical Process Control