|
PD02
IMPLEMENTATION, INTEGRATION & MANAGEMENT OF
PREDICTIVE MAINTENANCE
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 a
Predictive Maintenance strategy through a project-based implementation and
maintaining that strategy through good management techniques. They will learn
why the best companies in the world see Predictive Maintenance as the key to
delivering optimal production functionality by securing a thorough knowledge of
equipment condition.
THE COURSE
Predictive
Maintenance is one of several techniques which are critical for a successful
company and an integral part of maintenance management strategies such as RCM,
RBM TPM, and even 6-Sigma. 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 Predictive Maintenance system or
auditing an existing system. It covers all the steps required in developing a
successful Predictive Maintenance programme from initial recognition of a
problem, through management approval and system development until a well managed
Predictive Maintenance system is in place and operational.
THE DELEGATES
It is
recommended that all 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
-
To provide a
step-by-step guide to developing a Predictive Maintenance system starting with
foundations and building up to best practice that will deliver maximum
business benefits.
-
To provide
opportunities to discuss the implementation and integration within the
production environment.
-
Provide an
opportunity to learn these concepts through practical exercises
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
Start
with a justification to management to get capital and operational funding. This
includes a description of the problem(s) and overview of the solution(s).
Introduction
Seminar overview identifying objectives and goals
Associate the delegates to teams for workshop activities
Introduction to Predictive Maintenance technologies.
Identify the Problems
Basic reliability overview with statistical analysis of rotating
equipment
Pareto analysis and identification of bad actors
Cause Mapping & FMEA
Prepare the solution for management
Cost analysis of PdM –v- Status Quo
Resource analysis
Prepare the presentation to management for budget authorisation
Day 2
Design a project to implement the initial stages such as software installation,
equipment demographic analysis etc.
Potential Failure Analysis (PFA)
Identify the failure mechanisms
Identify suitable measurement technologies
Prepare detailed PFA’s for the subject equipment
Acquire the Resources
Prepare technical requirement specifications
Vendor/equipment selection
Define manpower requirements & job descriptions
Define and acquire logistical support
Define the project
Software tools
Equipment demographic analysis
PERT & GANTT charts
Resource levelling
Day 3
Manage
the project and the capital budget. This stage involves periodic progress
reports to management.
Roll out the project
Change management
Define the pilot project area
Post pilot rollout
Continuous Improvement
Training
Procedures
PFA as part of ISO 9000
Project Progress Reporting
Functional –v- operational reporting (project)
Routines, procedures, processes
Define progress reports (budgetary & technical)
Day 4
Handover
of the project to the operational division. At this point we have to consider
how to integrate the operational aspects of the new way of working so that the
production and maintenance teams are involved.
Work Practices
Technical qualification
Functional responsibilities
Functional –v- operational reporting (routine)
PdM work flow
Reporting
Define report content
Getting the recommendations to where they do most good
Overview reports
Continuous Improvement
Alarm triggers
Case history reviews
PFA modification
Day 5
Develop
Key Performance Indicators so that managers can maintain control of the process.
CMMS Integration
CMMS requirements
Operational planning
Key Performance Indicators
Reliability & statistics – MTBF, Reliability etc.
Work request backlog analysis
Customer feedback analysis
Cost analysis
| 