Certificate Course in Creating Maintenance Excellence

What are the Goals?

By the end of the Certificate Course in Creating Maintenance Excellence training course, participants will be able to:

• Understand the basic principles of Asset Management as a framework for managing and optimizing maintenance
• Identify common maintenance Key Performance Indicators (KPIs) and develop the maintenance department scorecard
• Assess the organizational Asset Management maturity and develop a roadmap for improvement
• Examine the organizational and managerial considerations for highly effective Risk Based Maintenance
• Understand Life Cycle Management and the way Systems Engineering and RAMS could support this
• Determine the Life Cycle Costs of an asset
• Demonstrate the latest concepts and techniques with regard to Predictive and Smart Maintenance
• Set up master data to support asset maintenance
• Facilitate the development and implementation of programmed maintenance
• Develop task plans and procedures that meet safety, quality and efficiency criteria
• Initiate the acquisition of logistics to enable execution of backlog work
• Compile a work schedule for a forthcoming period in consultation with stakeholders
• Produce performance indicator based reports that expose problem areas

Who is this Training Course for?

This training course is suitable to a wide range of professionals involved in the area of creating maintenance excellence, but will greatly benefit:

• All professionals involved in Maintenance Management
• Professionals involved in work planning & control (planners, planning engineers)
• Maintenance supervisors
• Maintenance engineers
• Maintenance team leaders and managers
• Operations team leaders and managers

Daily Agenda

Day One: Introduction to Asset Management – a Framework for Managing & Optimizing Maintenance

• Asset Management as a business process
• Asset Management Landscape Model
• Strategy framework
• Line of Sight
• Asset Management policy, Asset Management strategy
• (Strategic) Asset Management Plan
• The position of Maintenance Management
• Asset Management roles on strategic, tactical and operational level
• ISO 55000 – the international standard on Asset Management

Day Two: Assessing Asset Management Maturity as a Basis for Maintenance Improvement 

• Measuring performance
• Leading & lagging indicators – KPI – dashboards
• Assessments & benchmarking against international standards
• Asset Management maturity assessments
• Asset Management workbench (ISO 55000 gap analysis)
• SAM-assessment (ISO 55000 self-assessment)
• Determine the roadmap for maintenance improvement
• The business case for Asset Management improvement – cost/benefit thinking
• Implementation aspects

Day Three: Managing Asset Risks – Risk Based Maintenance (RBM) 

• Not every failure is important - the basic principles of risk
• Risk on business level
• Risk matrix, risk register
• Risk on asset level
• Failure behaviour of systems
• Choosing the appropriate maintenance tasks for your assets with a Risk Based approach

Day Four: Life Cycle Management

• Life Cycle Management
• The life cycle of an asset
• Demand forecasting
• Creation & acquisition of assets
• Systems Engineering approach
• RAMS requirements – methodologies
• Life Cycle Costing (LCC)
• Disposal and/or replacement - Life time extension (asset rationalisation)

Day Five: Smart Maintenance

• Understanding principles of Predictive Maintenance (PdM)
• What PdM technologies to apply – a short overview of relevant PdM technologies
• Smart Maintenance – measuring asset performance with modern data technology
• Data analysis aspects
• Optimization aspects – optimizing the maintenance strategy
• Using decision support tools

Day Six: The Building Blocks of a Modern Maintenance Management System

• The ‘Asset Healthcare Model’
• Asset master data
• Organisation master data
• Maintenance logistics planning

Day Seven: Programmed Maintenance Development and Planning

• Criticality grading
• Failure modes and effects analysis
• Programmed task selection criteria and tools
• CMMS task plans and work orders
• Corrective maintenance task procedures

Day Eight: Work Management

• Work management process model
• Defect reporting and notifications
• Backlog control
• Capacity planning and resourcing
• Schedule with consensus of stakeholders

Day Nine: Shutdown and Turnaround Management

• Network planning and critical path scheduling
• Resource profile
• Resource levelling and balancing to optimise the schedule and resource profile
• Shutdown and turnaround progress tracking and control

Day Ten: Performance Management

• Setting up performance indicators and data sources
• Work management performance indicators
• Asset maintenance effectiveness performance indicators
• Cost control performance indicators
• Planning performance indicators