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Optimising Equipment Maintenance and Replacement Decisions

ENDED
Training by  CITED
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On-Site / Training
Ended last Oct 15, 2021
NGN  120,000.00

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

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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.

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