Maintenance Systems and Documentation addresses the main systems necessary for the successful operation of a maintenance organization, such as performance control, work control and documentation. It shows how they can be modelled, their function and operating principles, and the main problems encountered in operation.

Upon successful completion of this course, the delegates will be able to:

• Apply and gain knowledge on maintenance systems and documentation
• Understand maintenance operations, in order to identify problems and prescribe effective solutions
• Provide maintenance professionals in any sector with a better understanding of maintenance management, enabling the identification of problems and the delivery of effective solutions
• Focus on the main systems necessary for the successful operation of a maintenance organization
• Discuss maintenance of plant, production and operations assets in industry and service sectors, including manufacturing, food and process engineering, minerals and mining, transport, power and IT
   

This course is intended for maintenance, plant, production and operations engineers in any industry sector. 

Day 1:

A Business-Centered Approach to Maintenance Systems

Introduction

Business-centered maintenance

An example of the application of BCM: background

Audit of the FPP maintenance department

Maintenance objectives

Life plans and preventive schedule

Workload

Maintenance organization

Maintenance work planning

Maintenance control system

Maintenance documentation

Audit summary

An alternative maintenance strategy for continuous operation

A longer-term view of organizational change

The strategic thought process

Introduction to maintenance management systems

The company expressed as a hierarchic systems model

Identifying the maintenance systems

Budgeting and control

Day 2:

Maintenance Budgeting

Introduction

Maintenance budgeting

The budgeting procedure

Maintenance Management Control

Introduction

The basics of maintenance management control

Principles of maintenance management control

The control of overall maintenance performance

The control of maintenance effectiveness (the control of plant reliability)

Reactive control of plant reliability

Pro-active control of unit reliability

The control of organizational efficiency

Incorporating systems into the organization

Published methods for measuring maintenance performance

The use of indices of maintenance performance for inter-firm comparisons

Human factors and data collection

Day 3:

Work Planning and Work Control

Short-term Work Planning and Control

Introduction

The fundamentals of work planning

Modeling the operation of a short-term work planning system

The shift work planning system

The weekend work planning system

Feedback of maintenance data for control

Comments on work planning and work control

Guidelines for the design of work planning systems

Safety aspects

Network Analysis

Management of Plant Turnarounds

Introduction

Terms, concepts and definitions in network analysis

The network planning procedure

Data collection

Constructing the logic diagram

Establishing the critical path, floats and overhaul time

Deriving a bar chart from the network

Resource histograms

Comments

Day 4:

Turnaround Methodology

Management of Plant Turnarounds

Introduction

Initiating the turnaround

Forming a policy team and appointing a turnaround manager

Key policy decisions for the initiation phase

Selecting a preparation team

Collecting the job lists and other data

Preparing the turnaround

Analyzing and validating the work scope

Freezing the work list

Preparing task specifications

Identifying pre-shutdown work

Defining contractor work packages and selecting contractors

Creating the work schedule

Techniques for creating a schedule

Optimizing the schedule

Forming the turnaround organization

Defining the site logistics

Formulating a cost estimate

Formulating a safety plan

Formulation of the quality plan

Briefing of all turnaround personnel

Executing the turnaround

The shutdown of the plant

Carrying out the turnaround tasks

Defining and costing the extra work

Defining and costing additional work

Monitoring progress, productivity, safety, quality and expenditure

Starting up the plant

Terminating the turnaround

Spare Parts Management

Introduction

Outline of the stores operation

Inventory policy

Inventory policy for fast-moving spares

Inventory policies for the control of slow moving spares

Management of repairable equipment (rotables)

Introduction

The rotable system

Rotable inventory policy: the theory

Rotable inventory policy: in practice

Inventory policy guidelines

Stores documentation

Stores organization

Stores and rotable performance indices

Documentation

Day 5:

Maintenance Documentation Systems: What They are and How They work

Introduction

A functional model

Plant inventory

Information base

Preventive maintenance schedule

Condition monitoring

Short-term work planning

Long-term work planning

Maintenance control

Computerized Maintenance Information Systems: Their Uses and Problems

Introduction

Computerized documentation: historical background

The benefits of computerized maintenance information systems

The problems with computerized maintenance information systems

Case study: Maintenance Audit of an Agricultural Chemical Plant 201

Introduction

An overview of Fertec

Objectives

Comments on objectives

Maintenance strategy

Plant-operating characteristics

Ammonia plant maintenance strategy

Maintenance organization

Introduction

The maintenance resource structure

The maintenance administrative structure

Work planning systems

Short-term work planning, scheduling and control

The planning of the major shutdowns

Spare parts management

Introduction

Outline of the stores organization and systems

Maintenance control

The control of overall maintenance performance

The control of organizational efficiency

The control of maintenance effectiveness (plant reliability control)

Documentation 

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session