Introduction:

In an ever increasingly competitive marketplace, the maintenance department is routinely asked to keep equipment running longer, with fewer failures and at lower costs. Industry is experiencing the pressure of rising costs, foreign competition, and the need to improve work force productivity. Companies must make productive use of all their resources - labor, material, capital - through best maintenance practices. Planning, Management and Work Control has the greatest profit potential of any maintenance function — a "reliable” way to quickly improve maintenance performance and service.The program is intended to introduce participants to a deep and advanced knowledge of maintenance objectives, problems associated with poor maintenance program. A focuses are directed on maintenance documentation, maintenance strategies, reliability-centered maintenance, total productive maintenance, failure profile of plant machinery, acceptance standard and maintenance key performance evaluation and indicators. Computer applications on maintenance planning, maintenance scheduling, management and work control will be addressed too. Emphasis on various aspects of optimum maintenance sequencing, associated costs, replacement decision, task assignment & allocation, managing maintenance spare parts and problem solving process. In addition, trainees will learn how to sell management teams on the importance of these roles and how to gain the cooperation and understanding of purchasing, operations and engineering.This program is designed to be a hands-on, stimulating experience. The program is highly interactive with much discussion and computer application practice sessions.During the course, attendees will have the opportunity to review an "Interactive computer decision making and optimization applications”. Laptop computers will be available to join in a practical session.

By the end of this seminar, delegates will be able to go back to their facility and immediately apply what they learned to help make their plant or facility more efficient. Training like this never costs it pays!

Who should attend:

Delegates should represent a wide range of personnel in the organization who are involved and engaged or dependent on work management, planning, and scheduling and those who are looking for effective maintenance. These include:

• Maintenance Managers 

• Maintenance & Operations superintendents, supervisors, team leaders 

• Maintenance planners

• Key leaders from each Maintenance craft 

• Materials Management Managers/Supervisors 

• Key Maintenance support assistants 

• Other stakeholders in the Work Planning Function

Daily Outlines:

Day #1 

• Introduction

• Maintenance department’s function and objectives

• Apparent problems associated with poor maintenance program

• Selling Maintenance to senior executives 

• Maintenance documentation

• Maintenance documentation scenario

• Defining maintenance Strategies

Reactive, by default

• Preventive Maintenance PM

• Maintenance decision and computer applications 

• Condition based maintenance



Day #2 

• Reliability-centered maintenance 

• Modify the normal failure profile of plant machinery

• Acceptance Standard

• Presenting the RCM Plan

• Steps in developing a formal RCM analysis

• RCM Case Study

• Total Productive maintenance 

• Develop maintenance key performance evaluation and indicators 

• Backlog ratio

• Over age Backlog Schedule 

• Compliance

• Estimating Accuracy

• PM and Emergency Indices

• Overtime

• Productivity of the maintenance workforce Indicators

• Maintenance cost 

• Balance Sheet



Day #3 

• Maintenance planning 

• Planner qualifications 

• Planning Work Flow

• Good maintenance elements

• Preparing maintenance plan 

• Planning sheet

• Application planning sheet

• Building maintenance scheduling 

• Weekly Schedule

• Daily Schedules

• Case Study & Application

• Maintenance project management and planning module

• Evaluating Time-Cost Trade-off 

• Justify resource constrain 

• Optimum number of workers



Day #4 

• Optimum maintenance sequencing 

• Interactive practical applications 

• Track associated costs

• Machine replacement analysis (MRA) 

• Replace Sudden Failure Items

• Replace Items that deteriorate

• Computer Method for Machine replacement

• Life cycle costing analysis LCCA 

• Allocate maintenance work 

• Interactive practical applications 

• Planning of spare parts (Maintenance Material Control)

• Stock holding costs

• Stock ordering costs 

• Lead time elements

• Economical order quantity EOQ

• Computer applications in maintenance material control,

• Materials requirements planning (MRP) 



Day # 5

• Best maintenance Practice

• Problem Solving Process 

• Basic Types of Failure Causes

• Define the Problem - the problem Statement

• Gather Data/Evidence

• Identify the Fundamental Relationships associated with the defined problem. 

• Utilize and analyze diagrams

• Causes of failure

• Case History

• Identify, implement effective solutions and the recommendations

• Failure Mode and Effects Analysis (FMEA)

• Case study 

• Questions/Discussion and Wrap-up