Optimizing Equipment Maintenance & Replacement Decisions

Course Code: EM23

Course Objective

  • Identify equipment failures, and the impact on plant reliability
  • Understand the cost-effectiveness of Preventive / Predictive Maintenance program
  • Apply techniques of optimisation of various maintenance activities
  • Define criteria for work-crew size, spare parts and equipment replacement
  • Make the important decision on the basis of the cost and benefit analysis
  • Incorporate safety objectives to the equipment repair or replacement optimisation

 

Target Audience

  • Operation, Technical Production & Service Professionals
  • Technical Professionals responsible for maintenance and repair of equipment
  • Professionals involved in inspection and reliability
  • Technical Professionals dealing with risk assessment and integrity analysis
  • Technicians dealing with regulating and metering and other measurements

 

Course Outline

DAY 1: Physical Asset Management & Failure Analysis

  • Physical Asset Management
  • Maintenance Management: Preventive / Predictive Approach
  • Nature and Modes of Equipment Failure
  • Failure Modes & Effect Analysis (FMEA)
  • Analysis of Component Failure data using the Weibull Distribution
  • Censored Data, the 3-Parameter Weibull, and the Kolmogorov-Smirnov Test

DAY 2: Preventive Maintenance & Spare Parts Replacements

  • Reliability and Availability Concept: MTBF & MTTR
  • Reliability Improvement through Reduction of Downtime
  • Maintenance Performance Quantification
  • Preventive Maintenance & Spare Part Handling
  • Spare Parts Provisioning: Prediction Models and Techniques
  • Management of Change: In-Kind Spare Parts

​​​​​​​DAY 3: Equipment Inspection & Fitness for Service

  • Condition Monitoring & Inspection
  • Risk Based Inspection (RBI)
  • Risk Matrix: Management and Mitigation Measures
  • Reliability Improvement through Inspection
  • Inspection Scope & Frequency
  • Fitness for Service Analysis (FFS)

DAY 4: Economics of Maintenance, Repair & Replacement

  • Management of Maintenance Resources
  • Effective Use of CMMS
  • Maintenance Organization Analysis : Crew size
  • Equipment Repair or Replacement Decision
  • Economic Aspect of Maintenance Outsourcing: Subcontract
  • Economic Aspect of Equipment Replacement

​​​​​​​DAY 5: Total Productive Maintenance & Safety

  • Capital Investment in Equipment and Maintenance: ROI
  • Total Productive Maintenance
  • Safety in Maintenance Work
  • KPI and OEE: Leading and Lagging Indicators
  • Summary and Conclusions
  • The design of financial models for forecasting and decision-making


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Date & Location

Date : 01 April 2018

Duration : 5 days

Place : Dubai

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Date : 18 November 2018

Duration : 5 days

Place : Kuala Lumpur

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Date : 16 December 2018

Duration : 5 days

Place : Istanbul

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