Optimising Equipment Maintenance and Replacement Decisions
Details
Introduction
Major world companies from the process and petrochemical industry have developed their maintenance practices based on the optimization 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 optimization 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.
This programme is intended to introduce the participant to the process of making decisions regarding equipment maintenance optimization including equipment replacement. Various optimization techniques will be presented and the optimization criteria explained. The programme will include several workshops with case studies and real world problems to be solved. This will enable all participants to actively take part in the team work and classroom discussions
Programme objectives
At the end of this seminar, you will learn to
Understand the importance of Physical Asset Management
Identify the modes of equipment failures, and the impact on plant reliability
Understand the cost-effectiveness of Preventive/Predictive Maintenance program
Apply techniques of optimization 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
Outline
Programme Content
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 Kolomorgov-Smirnov Test
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
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)
4 - Economics of Maintenance, Repair & Replacement
Management of Maintenance Resources
Effective Use of CMMS
Maintenance Organisation Analysis : Crew size
Equipment Repair or Replacement Decision
Economic Aspect of Maintenance Outsourcing: Subcontract
Economic Aspect of Equipment Replacement
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
Schedules
No. of Days: | 3 |
Citadel for Technological and Engineering Dev. (CITED), a leading organisation in rendering quality service in Corporate Training, Manpower Development and Continued Professional Development (CPD) of Engineers, Technologist and Technicians have been in existence for over twenty years bringing quality service to Nigerians and Nigerian Engineers. Our portfolio of programs is renowned for its breadth and depth of focus, the caliber of its speakers, its interactive, practical and result-orientated nature, and the diverse and national range of participants. It is an excellent networking opportunity.
CITED programs also offer concrete toolkits of effective and practical techniques, strategies and skills to take away. The content continually evolves in response to new business. Our workshops are designed specially for individuals interested in or currently using engineering/technical expertise/skills and technologies to solve their organisation challenges.