Optimizing Equipment Maintenance & Replacement Decisions

Start Date: 17 Sep 2017
End Date: 21 Sep 2017
Duration: 5
Country: Singapore
Category: Engineering and Technical Programs

Course Description


Is your equipment (fixed or mobile) failing before planned replacement?

Are you unable to execute maintenance tasks because spare parts are not available?

Have you made significant investment in CBM methods and tools but struggle to realize the benefit?

Do you have lots of data from oil analyses but still struggling to accurately predict your equipment breakdowns?

Do you know how to determine optimum asset life?

Are you struggling to justify the economics of asset replacement?

Are you having difficulties in deciding whether to rebuild or replace your equipment to minimize the life cycle costs?

Do you need to optimize your emergency spare requirements?

Course Objective


The objectives of the program can be summarized as follows:

         To focus on the techniques of optimization - the single most important thrust of this learning program. Whether the decision is about work-crew sizes, or the replacement of component-parts or entire equipment units, the concept of making the very best, most optimal, decision will be the principal concern of the training program.

         To equip the participating maintenance managers, planners and schedulers and engineers with the know-how to select the most appropriate analytical tools for their maintenance decision-making.

         Reflecting the growing focus of industrial safety and the profusion of safety-related litigation - think of transportation accidents, chemical spills, and mining disasters - the program will show how safety objectives relate to the optimization models, and will underline the advantages of having a well-documented and rigorously-executed program of maintenance and replacement.

         To introduce the critical decision-making topics that can make a significant difference to the in-service time of equipment, to the costs related to doing maintenance too often or too seldom, and the optimization of asset utilization.

         To not only cover the classic need-to-know material in the area, but to acquaint the participants with leading-edge and on-the-horizon approaches that they will encounter in the near future.


Training Methodology

The course will combine presentations with interactive practical exercises, supported by numerous case studies. Delegates will be encouraged to participate actively in relating the methodologies and tools presented during the 5-day course to the particular needs of their workplace.

Organisational Impact

Focus on the most advanced techniques for Maintenance Optimization

         Select the most appropriate Analytical tools for maintenance decision making

         Relate Safety objectives to optimization models

         Introduce Critical Decision-Making Topics

         Acquaint with Leading-Edge and On-The-Horizon approaches

         Continue to Apply the Course-Learning to your workplace problems

Personal Impact

         Equipment maintenance and replacement decision are frequently based on informed opinions or subjective responses to common situations. In this course, we will deal with procedures based on careful research that is firmly rooted in reality. The course is intended to give you the tools needed to make data-driven decisions, which you can apply in your own environment and upon which you can rely to help you in developing appropriate programs. With so much data available, we often find ourselves in the bewildering position of being data rich but information poor. We may have all the raw data well ever need at our fingertips; but unless we can interpret and integrate it properly, it is of little use. To refine this data into useful information, we need the appropriate tools.

         This course is designed to give you those tools. Our time is limited, and our individual interests and concerns vary. So we may not solve your particular problems in this course. However, I hope it will at least provide you with the concepts and techniques you need to address problems that arise as you carry out your responsibilities.


Who Should attend?



         Professionals of Plant operations

         Facility Professionals

         Maintenance or Reliability professionals who are responsible for maintaining and managing the physical equipment assets of a Plant/Facility

The ideal candidate for this seminar is an Engineer, Professional of Plant operations, Facility Professional, Maintenance or Reliability professional who is responsible for maintaining and managing the physical equipment assets of a Plant/Facility. He or she represents large Facilities and Plants from industries such as Oil and Gas, Petrochemical and Fertilizer, Pulp and Paper, Cement and Ceramics, Power Generation and Utilities, Primary Metals, and Heavy Manufacturing and Facilities.

Course Outline


Day 1

Physical Asset Management & Reliability Concepts

From Maintenance Management to Physical Asset Management

         Challenges of physical asset management

         The maintenance excellence pyramid

         Reliability through the operator: Total Productive Maintenance

         Reliability by design: Reliability Centered Maintenance

         Optimizing Maintenance & Replacement Decisions

Reliability Improvement through Preventive Maintenance

         Analysis of Component Failure Data

         Probability Density Function

         Reliability Function

         Hazard Function

         Weibull Density

         Infant Mortality

         Bath-Tub Curve

Exercise in Analysing Component Failure Data Using the Weibull Distribution

         Estimating the Weibull Parameters

         Using Median Rank Tables

         The role of the RelCode software Package

Dealing with Censored Data, the 3-Parameter Weibull, and the Kolomorgov-Smirnov Test

         Upper-End Censoring, Multiply Censored Group Data

         Estimating the Location Parameter in the Weibull Distribution

         Checking the Goodness-of-Fit of the Distribution

Day 2

Reliability Improvement through Preventive Maintenance (continued)

         Component Replacement Procedures including Glasser's Graph

         Block Replacement Policies

         Age-Based Replacement Policy

         Setting Policies based on Safety Constraints, Cost-Minimization and Availability-Maximization

         Repairable systems

Case Studies in Component Preventive Replacement

         Including boiler plant, bearings, pumps, sugar feeds, compressor valves, and centrifuges

Spare parts provisioning

         Fast moving spares

         Emergency (insurance) spares

Case studies in spares provisioning

         Including line replaceable units (LRUs), cylinder heads, repairable conveyor electric motors and utility transformers

Group and individual exercises


Day 3

Reliability Improvement through Inspection

Inspection Frequency and Depth for equipment in continuous operation

         Inspection Intervals to Maximize Profit

         Maximizing Equipment Availability

         Inspection Intervals for Equipment Used in Emergency Situations (e.g. protective devices)

         Case studies including oil and gas field equipment such as pressure safely valves (for protective devices)

Health-Monitoring Procedures

         Proportional Hazards Modelling

         Spectroscopic Oil Analysis Programs

         Optimization of Condition-Based Maintenance Procedures

         Role of software for CBM optimization

         Case studies including food procession industry (vibration monitoring), pulp and paper and shipping equipment such as compressors (vibration monitoring) and diesel engines (oil analysis), turbines in an electrical generating station (pressure measurements)

Demonstration of software for optimizing condition-based maintenance decisions


Day 4

Reliability Improvement through Asset Replacement

Aspects of Discounted Cash Flow Used in Capital Equipment Replacement Analysis

         Estimating the Interest Rate Appropriate for discounting

         Present-Value Calculations

         The effects of Inflation in the Analysis

         Calculating the Equivalent Annual Cost (EAC)

Economic Life of Capital Equipment

         The "Classic" Economic Life Model

         Before-and-After Tax Calculations

         The Repair-vs-Replace Decision

         Life-Cycle Costing

         Technological Improvement

Case Studies in Capital Equipment Replacement

         Including seamers in the food processing industry and combustion engines in the oil and gas sector

Group and individual exercises

Clinic: Hands-On Use of PC Software for Capital Equipment Replacement Analysis

         Participants will solve pre-set problems

Day 5

Effective Use of Maintenance Resources

Organizational Structure, Crew Sizes, Workshop Resource Requirements

         Balancing Maintenance Costs against Plant Reliability

         Establishing the optimal number of machines to have in a workshop

         Resource Requirements Using Queuing Theory and Simulation

         Utilization of Outside Resources

         Lease-Vs-Buy Decision

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