Optimising Equipment Maintenance & Replacement Decisions

What are the Goals?

By the end of this training course, the participants will be able to:

• Identify equipment failures, and the impact on plant reliability
• Understand the cost-effectiveness of Preventive/Predictive Maintenance program
• Apply techniques of optimisation of various maintenance activities
• Define criteria for work-crew size, spare parts and equipment replacement
• Make the important decision on the basis of the cost and benefit analysis
• Incorporate safety objectives to the equipment repair or replacement optimisation

Who is this Training Course for?

This training course is suitable to a wide range of professionals but will greatly benefit:

• Operation, technical production & service professionals
• Technical professionals responsible for maintenance and repair of equipment
• Professionals involved in inspection and reliability
• Technical professionals dealing with risk assessment and integrity analysis
• Technicians dealing with regulating and metering and other measurements

Daily Agenda

Day One: Physical Asset Management & Failure Analysis

• Physical Asset Management
• Maintenance Management: Preventive / Predictive Approach
• Nature and Modes of Equipment Failure
• Failure Modes & Effect Analysis (FMEA)
• Analysis of Component Failure data using the Weibull Distribution
• Censored Data, the 3-Parameter Weibull, and the Kolmogorov-Smirnov Test

Day Two: Preventive Maintenance & Spare Parts Replacements

• Reliability and Availability Concept: MTBF & MTTR
• Reliability Improvement through Reduction of Downtime
• Maintenance Performance Quantification
• Preventive Maintenance & Spare Part Handling
• Spare Parts Provisioning: Prediction Models and Techniques
• Management of Change: In-Kind Spare Parts

Day Three: Equipment Inspection & Fitness for Service

• Condition Monitoring & Inspection
• Risk Based Inspection (RBI)
• Risk Matrix: Management and Mitigation Measures
• Reliability Improvement through Inspection
• Inspection Scope & Frequency
• Fitness for Service Analysis (FFS)

Day Four: Economics of Maintenance, Repair & Replacement

• Management of Maintenance Resources
• Effective Use of CMMS
• Maintenance Organization Analysis : Crew size
• Equipment Repair or Replacement Decision
• Economic Aspect of Maintenance Outsourcing: Subcontract
• Economic Aspect of Equipment Replacement

Day Five: Total Productive Maintenance & Safety

• Capital Investment in Equipment and Maintenance: ROI
• Total Productive Maintenance
• Safety in Maintenance Work
• KPI and OEE: Leading and Lagging Indicators
• Summary and Conclusions