Investing in Effective Maintenance - An Intensive 5 Day Training Seminar

Improving System Operational Success to achieve Safe and Profitable Operations

Course Instructor - V. Narayan BMech, DipEE, DIM (View Profile)

Course Outline

Why do we have safety or environmental incidents? Why do we suffer mission failures or production shortfalls? Is there a relationship between maintenance costs and system availability? Can you improve operational performance and reduce maintenance costs at the same time? If you are a manager, supervisor, engineer, logistics specialist an academic or other professional seeking an answer to any of these questions, this workshop will be able to help you. It is aimed at people with a stake in Operational Success working in Defence Services, Manufacturing Plants, Chemical, Pharmaceutical, Oil & Gas, Railway, Paper Industries, Contractors and other Service providers. You will learn ways to improve the performance of your plant as a result of better reliability and availability of your facilities.

Effective maintenance is the key, not merely more maintenance. Investing effectively in maintenance can help you to reduce the risk of HSE incidents, mission failures or loss of production due to equipment unavailability. In this workshop, you will learn a logical and structured approach to achieve your (organisation's) objectives.

Business success depends on how well we manage risk, so we begin with a discussion of quantitative and qualitative risks. Human failures are more difficult to manage, but they matter a lot, so we will address this subject in some detail. This leads us to pro-active and reactive ways to improve equipment reliability. You will learn about Root Cause Analysis, a powerful reactive problem-solving tool, and get a good understanding of where and how to apply the method. On the pro-active side, we will see how Reliability Centred Maintenance can help us plan our work and improve our equipment reliability significantly. While you should not expect to become RCA or RCM experts as a result of this workshop, you should certainly have a good understanding of both, and know where to apply them.

Implementation of the results of analysis is of course the key to reaping the benefits. Analysis is the easy bit; implementing the results always poses challenges. So we will see how to grind away at the hard parts - writing new maintenance routines, scheduling work, then doing it on time, recording history, and hopefully, getting rewarded. Finally we will see how to implement change successfully. For this we need to understand critical success factors, change management, the importance of good communication and how to track progress. Sustained improvement needs a process to hold the gains.

The structure and content of this workshop will help you formulate action plans that can significantly improve safety, production, mission success and cost performance.

Workshop Preparation

We will send you a limited amount of pre-reading material. In order to reap the maximum benefit from the workshop, we request you to go through this material, and answer the questions by e-mail. Please bring some case examples of typical problems that you face in your work situation where you feel the material covered in the workshop may be of assistance.

DAY ONE

Introduction and Objectives

Factors affecting System operational success

Quantitative risk

Qualitative risk

Performance measurement

Data recording

DAY TWO

Human factors

Human error and its causes

Video and discussion

Learning from failures

Performance measurement

Problem solving process - Root Cause Analysis

DAY THREE

Planning for success

Understanding the nature of failure

RCM principles and methodology

Task-bundling

DAY FOUR

Preventive maintenance routines and maintenance management systems

Scheduling

Work execution

Compliance

Reward systems

Performance monitoring

DAY FIVE

Implementation

Reporting results

Lateral learning

Holding the gains

Workshop summary and closing

Problem solving process - Root Cause Analysis