DEFINE | Management Consultancy & Training

OPTIMIZING EQUIPMENT MAINTENANCE & REPLACEMENT DECISIONS

Location

Dubai, UAE

Date

From Date: 15-Jan-2024
To Date: 19-Jan-2024

Duration

5 Days

Language

English

Discipline

Mechanical Engineering

Introduction

Major world companies from the process and petrochemical industry have developed their maintenance practices based on the optimisation of predictive maintenance management system. This approach works well for both stationary and rotating equipment and includes continuous condition monitoring and the detailed inspection of vital elements of the equipment. The optimisation of the maintenance activities includes the spare parts handling, the selection of the right size and skill of maintenance crew with consideration of potential outsourcing i.e. subcontracting. Based on the collected data on reliability of the equipment in operation, Maintenance department can complete the Fitness for Service analysis based on which the decision can be made about 3Rs: Run, Repair or Replace, for the particular component of the equipment. Final decision regarding equipment replacement depends very much on the economic and safety aspect that must be taken into consideration.

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 optimization

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

Content

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

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

The training course will be highly participatory and the course leader will present, guide and facilitate learning, using a range of methods including formal presentation, discussions, sector-specific case studies and exercises. Above all, the course leader will make extensive use of real-life case examples in which he has been personally involved. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

30% Lectures
30% Workshops and work presentation
20% Case studies & Practical Exercises
10% Role Play
10% Videos, Software or Simulators (as applicable) & General Discussions

Case Studies, Group Discussions, Last Day Review, Assessments will be carried out.

Course Details