MODERN MAINTENANCE MANAGEMENT

BACKGROUND

As the requirements for improved productivity and cost effectiveness increase, combined with an increased attention to safety and environmental issues, maintenance activities play an important role. Modern maintenance management techniques will give a significant contribution to a company’s productivity by applying reliability based techniques and cost-benefit analysis for maintenance optimization.

Several companies have experienced the positive effect of improving maintenance management, achieving a better foundation for making the right decisions, and thereby reducing the amount of unplanned maintenance tasks and subsequently unplanned shutdowns.

WHAT PARTICIPANT WILL LEARN

ü  Modern maintenance techniques and methodologies that conform to the fast growing industries in the world

ü  Why we should use total maintenance strategy and benchmarking with world class industries to increase maintenance performance and cost effectiveness

ü  How to optimize the running operation of assets to a much - much longer compared to that generally applied without sacrificing their performance and conditions and at all times preserving their functions?

ü  Is applying Pareto in the diversified assets worth doing?

ü  Understanding the differences between failure management and failure prevention to preserve function of assets in their performance standards

ü  New paradigm of modern maintenance management approach, to totally transform the archaic maintenance conducts to a new, logical and effective maintenance management of the future?

ü  The modern maintenance methods duo from western and eastern school of thoughts that will embracing and conquer all kind of industries: Reliability Centered Maintenance (RCM) and Total Productive Maintenance (TPM)

ü  Human resources management of change in maintenance to face the fast growing modern industries in the world

ü  Some notes on Computerized Maintenance Management System (CMMS) and how to improve and optimize their input in the effort to optimize the volume of works and their intervals using decision support tool software

ü  Spare optimization system in attempting a drastic reduction in expensive maintenance inventory

ü  Is repairing components worth doing? Is non OEM component can be justified? An approach to implement good efficiency drive program

ü  The very basic maintenance philosophy one can not deny: clean, tight and lubricate and how to implement these correctly in almost all industries (an old maintenance approach to even ultra modern assets)

ü  A good maintenance is a simple maintenance, an old good maintenance view even in the modern maintenance approach

COURSEOUTLINE

1. TYPE OF MAINTENANCE METHOD

ü  Preventive maintenance

ü  Predictive maintenance

ü  Corrective maintenance

ü  Proactive maintenance

2. TYPE OF MAINTENANCE MANAGEMENT

ü  Basic Maintenance Management

ü  Reliability-Centered Maintenance (RCM)

ü  Risk Based Maintenance (RBM)

ü  Total Productive Maintenance (RCM)

3. BASIC MAINTENANCE MANAGEMENT

ü  Organizing maintenance activities

ü  Effective maintenance planner

ü  Maintenance scheduling and critical path

ü  Maintenance budgeting

ü  Maintenance job order

ü  Asset and spare part management

4. MAINTENANCE BASED ON RCM

ü  RCM Decision Diagram

ü  Planning, organizing, and controlling the proposed task

ü  Implementing RCM

5. MAINTENANCE BASED ON TPM

ü  Organizing, implementing and socializing TPM

ü  Product and equipment management

ü  Quality management system

ü  Administration system

ü  Evaluating and improving TPM result

6. MODERN MAINTENANCE MANAGEMENT IN PERSPECTIVE

ü  Maintenance in the business process

ü  Evolution in maintenance management

ü  The business objectives and maintenance objectives

ü  Business, operations and maintenance key performance area

ü  CMMS requirement

7. ASSET AND SPARE PART MANAGEMENT

ü  Equipment identification and type classification

ü  Part number and bill of material

ü  Documentation structures, identification, and classification

ü  Logistic planning

ü  Logistic support analysis

ü  Critical path analysis

8. MODERN MAINTENANCE MANAGEMENT APPROACH

ü  Modern maintenance techniques and methodologies

ü  Total maintenance strategy and bench marking to increase maintenance performance and costs effectiveness

ü  Optimization of running operation of assets along with its preservation at all times their functions?

ü  Pareto principle in the diversified assets

9. NEW PARADIGM IN MODERN MAINTENANCE AND FAILURE MANAGEMENT

ü  New paradigma of modern maintenance management approach, to totally transform the archaic maintenance conducts to a new, logical, and effective maintenance management of the future?

ü  Understanding the differences between failure management and failure prevention to preserve function of assets in their performance standards

1. SUCCESSFUL AND PROVEN MAINTENANCE TECHNIQUE AND METHODOLOGY IN INDUSTRIES

ü  Total Productive Maintenance (TPM) its foundation and strength

ü  Reliability Centered Maintenance (RCM) its foundation and strength

ü  Human resources management of change in future maintenance management

ü  Beware to system operation and maintenance procedures that is not optimized by RCM procedure that can caused catastrophic accidents to the assets.

1. INTRODUCTION, MAINTENANCE OVERVIEW

ü  Maintenance Goal

ü  Run to Failure (RTF)

ü  Scheduled Maintanance (Preventive Maintenance)

ü  Predictive Maintenance (Based Condition Monitoring)

ü  Total Productive Maintenance (TPM)

ü  Reliability Centered Maintenance (RCM)

2. MAINTENANCE STAKEHOLDER
3. PLANNING AND SCHEDULING OF MAINTENANCE
4. RISK PRIORITY NUMBER (RPN)
5. RELIABILTY, THE QUANTITATIVE PARAMETER OF MAINTENANCE GOAL

ü  Maintability based on RPN

ü  Availibility based on best performance of system

ü  Reliability Formula

6. COMPUTERIZED CALCULATION OF RELIABILITY
7. PLANT/SYSTEM RELIABILITY

ü  Paralel System

ü  Seri System

ü  Seri Paralel System

8. RELIABILITY DEGRADATION
9. IMPROVING RELIABILITY

PARTICIPANT

1. Staf Senior, Manager, dan Direksi.
2. Manajer Fungsional di bidang Health & Safety, CR, HR, Marketing & Communications.
3. Manajer dan Senior Manajer yang berkepentingan dengan ISO 26000.
4. Manajer dan Senior Manajer bidang Corporate Governance/ Compliance

Manajer dan Senior Manajer bidang Quality &  Environment, External/Government Relations & Project/Site.