|
MT03
RELIABILITY CENTRED
MAINTENANCE &
TOTAL PRODUCTIVITY MAINTENANCE’
INTRODUCTION
Increased
economic pressures have forced the maintainer to become more cost conscious.
Further, the application of new technology and the implementation of new
business practises mean that effective maintenance of plant and equipment
requires ever-greater technical and managerial skill. Reliability Centred
Maintenance (RCM) & Total Productive Maintenance (TPM) are proven cost effective
strategies for maintenance and achieve sharper maintenance policies, slimmer
budgets, increased availability and a more motivated workforce. To ensure
companies realise optimum maintenance they need to adopt strategies that
maximise availability and safety and minimise operating cost. These strategies
can be delivered using RCM & TPM and this seminar will show you exactly how.
THE RESULTS
Organizations
that manage the condition and optimise the performance of equipment in the area
of Maintenance are consistently able to better compete on the global stage. The
participants and their teams are better positioned to positively influence the
organization with innovative ideas and techniques that in turn produce a higher
performing organization.
THE BENEFITS
Individuals
exposed to this training will develop expertise in the area of developing RCM &
TPM. They will learn why the best companies in the world see RCM & TPM as the
key to delivering optimal production functionality by securing a thorough
knowledge of equipment condition.
THE COURSE
RCM & TPM are
techniques which are critical for a successful company. This comprehensive 5-day
programme has been designed to benefit both qualified new professionals as well
as experienced professionals who may be involved in the rollout of a new
Reliability Centred Maintenance system or auditing an existing system.
THE DELEGATES
It is
recommended that all senior and middle Maintenance, Reliability, Engineering and
technical support staff especially including leadership and management attend
this workshop. If you and your company are interested in greatly increasing
productivity, this will be a very valuable course
THE GOALS
The program will
expose the Maintenance and Production Personnel to understand the concept of RCM
and TPM. The following advantages of RCM are ensured to the participants:
-
Maintenance
strategy Optimization
-
Extension of
Equipment Life Span
-
Elimination of
Chronic Machine Problems
-
Root Cause
Analysis
-
No Preventive
Maintenance tasks to be performed unless it can be justified
-
TPM
THE PROCESS
This workshop is
designed to be a hands-on, stimulating experience. The program is highly
interactive with many discussion and facilitated practice sessions.
Contents:
·
Day 1
o
Reliability
Centred Maintenance
§
Introduction
of RCM
§
RMA
(Reliability, Maintenance and Availability) Concepts
§
Functional
Criticality Analysis
§
RCM Stages
and Tools – RCM, FMEA, FMECA, Road Map
·
Day 2
o
Total
Productive Maintenance
§
TPM Overview
– Breaking down Barrier, Hidden Losses, Cultural Change, New Mindset
§
TPM
Initiation – Philosophy of Awareness, Improvement Program Study, Setting up
Pilot Project
§
TPM Planning
– Agree & Assign Accountability, Design Zoning Policy, Critical Equipment
Analysis
§
TPM Action –
Tagging, Cando Procedures and Standards, KPI, Develop Focus Project, Discipline
Communication, Analytical Problem Solving, TPM Consolidation (Institutionalizing
Practices, Personal Development Review).
·
Day 3
o
Business
Process Re-Engineering
§
BPR Overview
– Functional Orientation, Losses, Methodology, Customer and Expectations.
§
Customer
Expectations – Types of Customer, Core customer, Typical Expectations,
Establishing Expectations, Objectives Measures and Targets.
§
Identifying
Primary Process, Selecting Re-Engineering Projects, Mapping Activities.
§
Business
Process Re-Engineering – Re-Engineering Process, Relational Mapping,
Characteristics, Re-Engineering Principles, Issues, Process Assumptions and
Constraints and testing.
·
Day 4
o
Applications
& Implementation
§
Continuous
Improvement
·
Closed Loop
Control
·
Targets and
trending
·
Problem
Solving
§
Implementation
·
Integrated
Team
·
Project
Management
·
Key Success
Factor.
·
Day 5
o
Engineering
§
Getting
Started – Assessment of Improvement potential,
·
Benchmarking,
·
Plant
Downtime Analysis,
·
Chronic and
Acute Failures,
·
Overall
Equipment Effectiveness
·
Statistical
Process Control
| 