RELIABILITY CENTERED MAINTENANCE

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1 Page 1 *************************************************************************************** RELIABILITY CENTERED MAINTENANCE BUILDING BLOCKS FOR RELIABILITY. **************************************************************************************** Connect. Share. Grow 1 P a g e

2 FEE: NGN 450,000 Per Candidate Exclusive of VAT Includes training materials & Meals Course Duration: 3 days Course Delivery Method: Face to Face Page 2 Course outcome: Attendees will gain an in-depth understanding of RCM, a World Class Methodology, and gain insight into how it could be applied to their site. They will learn how RCM can help develop an asset reliability strategy and assist in managing risk. Attendees: Anyone in manufacturing, processing or utilities with an interest in tackling reliability issues and proactively managing their assets. Previous attendees have included Engineering Managers, Production Managers, Maintenance Managers and members of their teams including Supervisors, Maintainers and Technicians. Benefits of an RCM maintenance strategy: lower manufacturing costs increased produc'vity improved equipment operating performance increased equipment availability reduced risk Reliability: A reliable asset is available to perform the functions for which it was intended to the required standards of performance whenever it is required. When a piece of equipment is optimally maintained there is an increase in cost effectiveness, machine uptime, and a greater understanding of the level of risk that the organization is managing. The RCM methodology provides the means to: 2 P a g e

3 Iden'fy the causes of failure Identify the cri'cality of failure Identify preventive measures Page 3 Item Key Topics Benefits 1 Foundation Identifies the types Reliability of situations that cause equipment Knowledge failure Physics of Failure Why parts fail Equipment Failure Curves Early Life Random Age Maintenance strategy selection Risk Management The components of risk Measuring risk Maximum Reliability Series and Parallel Systems Life-cycle considerations Quality and Precision Human Factors Explains why maintenance is done Explains equipment life-cycle strategies 2 Recognising Equipment Risk Equipment Criticality Identifying systems critical to plant safety and profitability and matching the maintenance effort. Activity 1 Perform Equipment Criticality Analysis Match maintenance and reliability management strategies to operating risk 3 P a g e

4 3 Identifying Effects of Failure Failure Modes and Effect Analysis (FMEA) Identifying failures and ways to eliminate them Identifying the root-cause Feasible ways (technically) of analysis Activity 2 Perform an FMEA Activity 3 Access Failure Consequences Methods to eliminate possible failure increases the reliability and integrity of equipment Page 4 Activity 4 Identify Hidden Failures 4 Proactive Maintenance Maintenance Strategy Selection Selecting Preventive and Predictive Tasks to maintain reliable plant equipment in the most cost-effective manner while meeting the challengeof regulatory compliance. Operating Risk Reduction with RCM to identify the most practical, cost- effective and technically correct tasks in maintaining equipment function Precision Maintenance and how workmanship quality produces high reliability Case Study1: Maintenance Strategy Activity 5: Maintenance Strategy Selection from FMEA Activity Highlight possible issues/challenges of maintenance Getting the bigger picture of the issues, possible solutions and benefits of implementation Which selections will actually deliver reliability improvements Activity 5: Maintenance Strategy Selection from FMEA Activity 4 P a g e

5 5 Making Reliability Centered Maintenance Work Changing to Better Maintenance Practices Purpose of RCM on-condition based maintenance RCM The 7 basic questions Describing and listing functions Performance Standards Applying the RCM process To get the increased reliability and integrity of equipment that RCM can deliver needs the proper practices to be introduced and used Page 5 What RCM achieves: Example RCM Maintenance Strategy Development Measuring likely improvement of RCM strategy Case Study2: Activity 6 Item Key Design/Topics B 5 P a g e

6 Page 6 TRAINING PROSPECTUS 6 Integration of RCM and Implementati on of Strategies Design Principles of Low-Cost, Usable, Reliable, Maintainable & Safe System Identifying Project and Operating Risk Setting Reliability Standards Reducing Operating Risk at Design Maximizing Availability Controlling Human Factors Quality Control setting pass/fail criteria Importance of Standardization Accuracy controlled procedures Case Study 3: Activity 8 Do an RCM on a Pump Set Metrics to track effectiveness of equipment Metrics to check the effectiveness of RCM implementation Proactive Condition Monitoring MTBF improvement measures Operational improvement measures The principles of reliable and maintainable, high performance plant Ways of integrating all the knowledge obtained and implementing it for the benefit of the organization Effective implementatio n uses key metrics to better utilize resources, enhance coordination among related projects and improve project planning and estimation; Proactively identify the risks of failing to complete the schedule and budget targets; reduce the process overhead of measurement data collection, consolidation and analysis at different levels in the project hierarchy How to make RCM really work 6 P a g e

7 Page 7 TRAINING PROSPECTUS 7 Optimize Your Maintenance Systems Creating a Useful Maintenance Management System Access, standardize all relevant information regardless of location and format (work orders, maintenance schedules, regulatory requirements, resource skills) Maintenance Planning and Scheduling Optimize RCM plans and schedules (taking into account priorities, skill sets, time and Resource constraints, etc); track work orders and resource usage Developing and Implementing RCM with a Limited Staff Standardize equipment and parts Precision Operation degradation management TPM - Operator Maintenance activities Precision Maintenance skill set Teamwork Organisation Structure Error-proofing work activities Easily share RCM knowledge benchmark standards best practices, maintenance history, regulatory guidelines, etc. among those who need it, in a form that works best for them Establish a mature maintenance process early in the plant life to maximize the effectiveness of the RCM program, minimize unnecessary activities, and increase the reliability and worth of plant & equipment RCM for sites with a small number of maintenance and operations staff 8 Looking Forward - Moderniza tion in Reliability Techniques of Reliability Growth Weibull Analysis recognizing failure causes Human Factors Management Reliability Growth Cause Analysis (RGCA) Activity 9 Conduct an RGCA Apart from the short RCM method covered in the course, there are new Maintenance Optimization ideas that can be used 9 Take Home Plan Case Study 5 Implementing RCM in the Australian Coal Industry Activity 10 Attendees identify list of activities to increase or optimize reliability at their facility and develop first-steps implementation plan Provide Attendees with initial actions to improve their plant performance by using RCM DO A WORKPLACE RCM ACTIVITY 7 P a g e

8 About The Maintenance Institute Africa We are Africa s foremost M&R organization offering up to date industry information, networking, training, solutions as well as a meeting point between industries and solutions provider across Africa. Our Page 8 solutions are designed with the professional in mind while aligning to global industrial best practices. Our course leaders are active industry professionals with accolades under their belt. Excellence is at the core of what we do at TMI and that s what we intend to impact as you join any of our sessions. You can learn more about The Maintenance Institute and register for our learning sessions Call Learn@tmiafrica.org About the Course Leader David Jonathan CMRP, CRL Mr. David is a Certified Reliability Leader (CRL), Certified Maintenance Reliability Professional (CMRP), Six Sigma Certified, and Field bus Certified Professional. Currently he serves as an active M & R practitioner in the oil and gas sector He is the founder of The Maintenance Institute Africa (TMI AFRICA) and organizational seeking to create synergy while promoting best practices among M&R professionals on the continent He is a Member of Society for Maintenance Professionals, Association for Maintenance Professionals, Fieldbus Foundation also an avid speaker at international M & R Conferences 8 P a g e