Course Methodology

This is a highly interactive course with short presentations on best practice and then a series of challenge exercises to take participants on a journey from basic maintenance to applying several world class leading approaches. The emphasis will be on teamwork in the exercises, guided discussion, a few videos and numerous case studies. 

Course Objectives

By the end of the course, participants will be able to:

• Apply award winning models of maintenance excellence to their own work place situations
• Participate in reliability improvement work with a new approach
• Understand the different types of maintenance and how to use them
• Apply the principles of maintenance excellence to change their approach to maintenance and reposition maintenance as a strategic function in their organizations
• Utilize key techniques and approaches to enable maintenance to have a more effective input in major projects and turnarounds

Target Audience

This course is suitable for all levels of maintenance practitioners. This includes but is not limited to; maintenance managers, maintenance supervisors, planners, project engineers, maintenance engineers, project managers, reliability engineers, operations team members and commercial managers who are active in maintenance.

Target Competencies

• Problem solving
• Cost analysis
• Workflow management
• People management
• Leadership

An introduction to the Maintenance Models of Excellence

• How maintenance has evolved
• Sources of best practice and benchmarking options
• The pitfalls of traditional maintenance practices
• The principles of cost-effective maintenance - where money should be invested and where money tends to be wasted
• A change in thinking
• Away from cost reduction or reliability or safety
• Towards cost reduction and reliability and safety
• Aligning maintenance with the business plan and managing for performance
• How maintenance adds value to bottom line profit

A holistic approach to Asset Reliability Improvement, the bigger picture

• Understanding the relevant management processes for any asset and operation
• The role of operations
• Getting projects right
• The reliability roadmap
• Improving process performance
• The principles of cost-effective maintenance investment
• Running maintenance improvements and dealing with some of the people issues
• Setting goals and KPIs to track progress

Improving reliability at equipment level

• Analyzing options to understand the underlying causes of inadequate equipment performance
• Root cause failure analysis
• Weibull analysis
• Criticality analysis
• Failure mode effects and criticality analysis
• Development of effective maintenance plans
• Reactive
• Preventive
• Predictive
• Proactive

Developing a high-performance team

• Developing an organization that will support the reliability and maintenance strategies
• Setting a reliability focused culture
• The roles of personnel outside maintenance in reliability improvement and how to engage the right people in the right way
• Leadership skills required to deliver full organizational performance

Work management - The Maintenance Process

• Optimizing the workflow process and CMMS system performance
• Modern workflow management processes

Improving maintenance performance

• The latest thinking in risk management
• Separating critical work from the nice to haves
• On Time In Full work execution
• Recording work done, learning and improving future work
• Planning and executing projects with added maintenance excellence included
• Managing maintenance materials and stores
• Use of computer-based technology
• The truths and the myths about the digital twins

A world class leading approach to Turnaround, Shutdown and Outage Management

• Why turnarounds are the most difficult thing we do
• Where people tend to go wrong
• The greatest weaknesses of maintenance professionals
• The model of excellence for turnarounds
• The golden rules to surviving and converting turnarounds from a high risk to an opportunity