Advanced Maintenance Strategies for Sustainable Reliability
Dates: 18th – 20th May 2025
Course Overview
Today’s modern process and manufacturing industries are complex and asset intensive. This requires that they be maintained in a manner that delivers a highly reliable operating environment which maximizes uptime whilst minimizing operational costs. In addition, plants and facilities must be maintained so that process safety and asset integrity are not compromised. Effective maintenance requires an understanding of current maintenance practices. This means having a clear perspective on areas requiring development, the capabilities to execute and a realistic plan for putting all of this in place. To do this in an efficient way, select skills are required to identify opportunities and effectively utilize modern technologies such as using sensors in conjunction with the Industrial Internet of Things (IIoT). Benefits realizing from applying asset management in this manner will contribute to the sustainable operation of a wealth-generating entity in a demanding economic environment. This masterclass will provide you with the skills necessary to do so and more. The course underscores the importance of interactions and cooperation between the three key functions related to modern manufacturing industry which are needed to achieve the optimum reliability level of a plant. These are engineering, operation and maintenance. It drives home this key issue with practical examples of significant failures that have resulting from a lack of understanding of the roles, responsibilities, and interfaces between these functions.
Learning Outcomes
| Day 1 | Day 2 | Day 3 |
| Foundation for Maintenance Excellence | Maintenance Strategies and Practices | Asset Care – Ensuring Sustainable Reliability |
| Module: 1. Asset Management: An Overview • Sustainability Principles, and • Impact of Incidents. | Module: 1. Changing the Status Quo • Failure Mode and Effects Analysis (FMEA), • Reliability Centered Maintenance (RCM), and • Exercise: Practical application of failure mode and affects analysis. | Module: 1. Problem Solving: A Maintenance and Reliability Perspective • Problem solving as maintenance planning and scheduling perspective: • Principles of problem solving, • Root cause analysis techniques, • Wicket problems and how to expose and address them, • Co-establishment of a problem-solving culture, and • Exercise: Root cause analysis case study. |
| 2. Managerial Terminology and Approach • Managerial Terms, and • Operational Integrity Management. | 2. Maintenance Strategies • Run to Failure Maintenance (RTF), • Corrective Maintenance (CM), • Preventive Maintenance (PM), • Predictive Maintenance (PdM), • Prescriptive Maintenance (RxM), and • Elimination – Improvement Projects | 2. Asset Management Improvement Practices • Project scoping • Project execution and coordination • Exercise: Scheduling (using a network diagram and a Gantt chart • Pitfalls in Reliability Improvement |
| 3. Generation of Wealth • Wealth Producing Enterprise, and • Plant Performance and Machine Lifecycles. | 3. Predictive Maintenance and Machine Condition • Equipment Failures and the P-F Curve, • Application of Condition Monitoring, and • Exercise: Asset Condition Assessment. | 3. Case study: • Gaining From Past Experiences |
| 4. Asset Management: Financials • Time Value of Money, • Estimating and Budgeting, • Life Cycle Cost (LCC), • Concept of Value in Asset Management, and • Exercise: Contribution of Maintenance to the Value Chain. | 4. Computer Supported Enterprise Asset Management • Leveraging the computerized maintenance management system (CMMS) • Artificial Intelligence and Machine Learning, • Industrial internet of things (IIoT), and • Concept of the digital twin and SMART Maintenance. | 4. Group Discussion: Utilizing the Knowledge Gained • Management of Change, and • The Next Step: What is yours? |
| 5. Organizational Aspects of Reliability • Functions and Roles, • Execution and Supervision, and • Training and Succession Planning. | 5. Critical Spares Management Optimization: • Classification of Spare Parts, • Quality Control Planning, and • Exercise: Optimization assessment | |
| 6. Risk Management and Asset Management • Fundamentals of Risk and Probability, • Risk Groups and Task Prioritization, and • Hazards and Risks. | 6. Impact Driven Asset Management® (IDAM) • Operations in a Complex Environment and the Sea of Detail, • Impact Driven Asset Management® Model, • Machine Map (Line of Sight), • Stages on the Drive to Peak, and • Reaping the benefits of Impact Driven Asset Management®. | |
| 7. Operational Integrity and Asset Management • The Starting Blocks, • Mastered the Act of Precision Maintenance, and • Principles in the Management of Data. | 7. Overview of Key Performance Indicators – Control of the Maintenance Process • Overview of Key Performance Indicators (KPIs), • Overall Equipment Effectiveness (O.E.E.), • Strategic and Tactical-Focused Performance Indicators, and • Scorecards and Reporting. |