COURSE OUTLINE

This course reviews the key concepts in Maintenance and Reliability with Condition Based Maintenance and RCFA as corner stones to the Reliability Improvement Program applied to critical equipment. Machine defects and fault findings originating from Inspection and Condition Monitoring programs are used to:

•       display equipment health;

•       identify risks;

•       action corrective work;

•       initiate Root Cause Analysis, and

•       identify and eliminate recurring failure modes … which is the cornerstone to a successful Reliability Improvement Program.

It is further supported by strategies such as Pro-Active and Precision Maintenance and Operator Driven Reliability (ODR) with specific focus on the role that people, and processes play in the maintenance and operational domains; particularly how this impacts on production throughput, production costs, production quality, safety and environment.

The course also investigates the impact that the 4th Revolution will have on maintenance and reliability, specifically referring to the implementation of twin technologies.

DAY-1 THE RELIABILITY IMPROVEMENT PROCESS OVERVIEW

Session-1.1   Asset Management

•          Asset management kernel

•          ISO 55000 outline

•          The Global AM Forum & AM Societies

•          ISO 55k continual improvement directive

Session-1.2    Reliability Introduction

•          Introduction to Reliability

•          Enterprise Reliability

•          4th Revolution Reliability (big data; edge computing, IIOT, AI, machine learning and twin technology impact)Session-1.3    Reliability – Management, Assurance & Improvement

•          Reliability and Continuous Improvement Kernel – Asset Hierarchy / Prioritisation / Maintenance Content optimisation / Maintenance Workflow / Condition Monitoring / Precision Maintenance / Operator Driven Reliability / Defect elimination

•          The Costs of Maintenance & Un-Reliability (COUR) as Improvement driver 

•          Reliability Management

•          Reliability Assurance

Workshop - Reliability & Maintenance Audits

 

DAY-2 PROACTIVE INTERVENTIONS - MAINTENANCE OPTIMISATION

Session-2.1    Optimising Maintenance

•          Equipment hierarchy 

•          Criticality

•          Maintenance History

•          Maintenance Content Optimisation

–         Reliability Centered Maintenance (RCM)

–         Plant Maintenance Optimisation (PMO)

•          Workflow Management

•          Procedure Optimisation & Training

•          Precision maintenance (installation, alignment, balance & electrical elements, lube application & contamination control)

•          Operator Driven Reliability

Session-2.2    Condition Based Maintenance

•          Condition Monitoring - Fundamental (Overview / Inspections / Vibration monitoring / Oil analysis / Thermography / Ultrasound)

•          Condition Monitoring - Specialised (Electric motor testing / Transformer testing)

•          Condition Monitoring - Implementation

Workshops – Criticality, RCM, CM & 4th Revolution Activities

DAY-3 REACTIVE INTERVENTIONS – DEFECT ELIMINATION

Session 3.0    Defect Elimination

Session 3.1     Introduction to RCFA

•          RCFA Terminology

•          RCFA Techniques (5 Why/Fishbone/Fault trees/Cause Mapping)

Session 3.2     Cause Mapping as the Basis to Risk Mitigation and Reliability Improvement

•          5-Why as Basis to Cause Mapping

•          Expanding the investigation

•          Blame vs. Prevention

•          RCFA vs. FMEA

•          Risk mitigation

Session 3.3     Important RCFA Elements

•          RCFA incident and equipment failure recording (FRACAS)

•          RCFA, risk and reliability relationship

•          RCFA scale

•          RCFA teams, facilitation & reporting

Workshop – RCFA

Feedback

What is it that the attendees have learned from the course and would wish to implement in their workplace.

WHO SHOULD ATTEND

·         Reliability and Maintenance Management [including Engineers, Senior Technicians, Maintenance and Operations Supervisors or Foreman]

·         Plant or Equipment Operators and Maintainers

OUTCOMES

On successful completion delegates will understand how to develop the best possible maintenance plans for each asset to ensure most effective yet least intrusive human/asset interaction; to eliminate adverse operational impacts and harness the power of the 4th Revolution technologies to achieve best possible asset reliability.

·         Understand the importance of:

•          The top five contributors to Reliability

•          The influence of processes and peoples on the assets

•          Both Proactive and Reactive initiatives to improve Reliability

•          The Defect Elimination (RCFA based) process

•          How to develop and apply a Prevention instead of a Blame culture during RCA investigations

·         Use the impact on company goals to scale RCFA investigations with related improvement actions

·         Identify solutions from the cause map that will avoid recurrence of failures

·         Establish a failure recording, analysis and corrective action infrastructure within the organisation

·         Harness the power of the 4th Revolution technologies.

 

Cape Town, South Africa

info@rcmi.co.za

+27 87 153-4560

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