By the end of this course delegates will be able to:

• Understand the need for an effective and World Class Maintenance Management
• Understand the importance of establishing the basics of maintenance
• Understand when to effectively use each of the different maintenance strategies
• Understand the importance of performing the basic maintenance disciplines
• Develop a Corporate Strategy for maintenance function
• Have a basic understanding on the 12 Disciplines of Maintenance Management
• Understand the real focus of a true and meaningful maintenance structure
• Learn what it takes to achieve a World Class Maintenance
• Learn the diversity of failures and how it occurs
• Understand the importance of Autonomous Maintenance
• Unfold the secrets of lubrication
• Learn why Preventive Maintenance cannot capture all equipment failures

TPM office staff, TPM facilitators, TPM managers, OE champions, Maintenance managers, engineers & planners, reliability and maintenance engineers, facilities and utilities managers, top level maintenance technicians, operations and production managers & engineers, plant engineers, design engineers, reliability engineers & technicians, operators, safety engineers, risk engineers, CMMS and spare parts personnel, safety engineers and anyone who is involved in reliability engineering strategies or methodologies.

Understanding Equipment Failures

• The Truth about Machinery and Equipment
• Is It Really Possible to Eliminate Failures and Breakdowns on our Equipment?
• What Maintenance is All About?
• Common Belief on Maintenance –Does All Parts Eventually Wear Out
• Limitations of Preventive Maintenance
• Understanding What Maintenance Can and Cannot Do
• Understanding Infant Mortality
• Random and Age-Related Failures
• 6 Types of Failure Patterns
• Classification of Failures –Hidden and Evident Failures
• Types of Failures –Function Loss and Function Reduction Failures
• Occurrences of Failures –Sporadic and Chronic Failure

Changing the Culture from Reactive Maintenance to Proactive Maintenance

• Reactive and Proactive Maintenance Explained
• Flowchart of a Reactive Maintenance Environment
• Learning the Correct Paradigm on Maintenance

Understanding World Class Maintenance Management

• World Class Maintenance Management Explained
• 12 Disciplines of Maintenance
• Basics, Intermediate and Advance Discipline

Discipline 1: The Need for Training and Skills on Maintenance

• Training and Skills Assessment-Steps to improve your current training needs
• Reflections and Learning’s from the first discipline

Discipline 2: Measurements and Maintenance KPI’s

• Most Common Mean Time Indicators
• Understanding Mean Time Between Failure (MTBF)
• Understanding Mean Time to Failure (MTTF)
• Setting Maintenance Goals and KPI’s-Reflections

Discipline 3: The Need for Autonomous Maintenance

• Why Autonomous Maintenance is Important
• Autonomous Maintenance Basic Concept
• Maintenance Guidance and Support for Autonomous Maintenance

Discipline 4: Addressing Basic Equipment Condition

• Importance of Going Back to the Basics
• Cleaning, Proper Lubrication and Tightening of Bolts
• Role of Operators in Establishing Basic Equipment Condition

Discipline 5: Addressing Basic Equipment Condition

• Preventive Maintenance Definition and Objective
• What Preventive Maintenance Activities Includes
• Feasibility of Using Preventive Maintenance for Age
• Related Failures-Survey of Top 10 Problems on Preventive Maintenance

Discipline 6: Lubrication Strategy and Management

• Function of oil and its composition, What causes oil to breakdown
• Understanding how contamination occurs
• Absolute and Nominal Filtration
• Filtration Efficiency and Beta Rating of Filters
• Oil Analysis, Testing Oil’s Health and Cleanliness
• How to remove contaminants from oil

Discipline 7: Understanding Life Cycle Management (LCM)

Discipline 8: Spare Parts Management

Discipline 9: Root Cause Failure Analysis (RCFA)

Discipline 10: Reliability Strategies: Reactive, Preventive, Predictive & Proactive Maintenance

Discipline 11: Understanding Condition Based Maintenance (CBM)

Discipline 12: Computerized Maintenance Management Software (CMMS)

Applying the Twelve Disciplines of Maintenance

CDGA attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.