Optimizing Equipment Maintenance and Replacement Decisions :: مركز المجد للجودة وتطوير الموارد البشرية

Training Course Objectives

To focus on the techniques of optimization – the single most important thrust of this learning program. Whether the decision is about work-crew sizes, or the replacement of component-parts or entire equipment units, the concept of making the very best, most optimal, decision will be the principal concern of the training program.
The concept of making the very best, most optimal, decision will be the principal concern of the training program.
To equip the participating maintenance managers, planners and schedulers and engineers with the know-how to select the most appropriate analytical tools for their maintenance decision-making.
Reflecting the growing focus of industrial safety and the profusion of safety-related litigation – think of transportation accidents, chemical spills, and mining disasters – the program will show how safety objectives relate to the optimization models, and will underline the advantages of having a well-documented and rigorously-executed program of maintenance and replacement.
To introduce the critical decision-making topics that can make a significant difference to the in-service time of equipment, to the costs related to doing maintenance too often or too seldom, and the optimization of asset utilization.
To not only cover the classic need-to-know material in the area, but to acquaint the participants with leading-edge and on-the-horizon approaches that they will encounter in the near future.

Training Course Content

Physical Asset Management & Reliability Concepts

From Maintenance Management to Physical Asset Management

Challenges of physical asset management

The maintenance excellence pyramid

Total Productive Maintenance

Reliability Centered Maintenance

Optimizing Maintenance & Replacement Decisions

Reliability Improvement through Preventive Maintenance

Analysis of Component Failure Data

Probability Density Function

Reliability Function

Weibull Density

Infant Mortality

Bath-Tub Curve

Exercise in Analysing Component Failure Data Using the Weibull Distribution

Estimating the Weibull Parameters

Using Median Rank Tables

Dealing with Censored Data, the 3-Parameter Weibull, and the Kolomorgov-Smirnov Test

Upper-End Censoring, Multiply Censored Group Data

Estimating the Location Parameter in the Weibull Distribution

Checking the Goodness-of-Fit of the Distribution

Preventive Maintenance & Spare Parts Replacements

Reliability Improvement through Preventive Maintenance(continued)

Component Replacement Procedures including Glasser’s Graph

Block Replacement Policies

Age-Based Replacement Policy

Setting Policies based on Safety Constraints, Cost-Minimization and Availability-Maximization

Repairable systems

Case Studies in Component Preventive Replacement

Including boiler plant, bearings, pumps, sugar feeds, compressor valves, and centrifuges

Spare parts provisioning

Fast moving spares

Emergency (insurance) spares

Case studies in spares provisioning

Including line replaceable units (LRUs), cylinder heads, repairable conveyor electric motors and utility transformers

Group and individual exercises

Clinic: Hands-On Use of PC Software for Preventive Replacement Strategies

Participants will solve pre-set problems

Machine Health Monitoring & Inspection

Reliability Improvement through Inspection

Inspection Frequency and Depth for equipment in continuous operation

Inspection Intervals to Maximize Profit

Maximizing Equipment Availability

Inspection Intervals for Equipment Used in Emergency Situations (e.g. protective devices)

Case studies including oil and gas field equipment such as pressure safely valves (for protective devices)

Health-Monitoring Procedures

Proportional Hazards Modelling

Spectroscopic Oil Analysis Programs

Optimization of Condition-Based Maintenance Procedures

Role of software for CBM optimization

Case studies including food procession industry (vibration monitoring), pulp and paper and shipping equipment such as compressors (vibration monitoring) and diesel engines (oil analysis), turbines in an electrical generating station (pressure measurements)

Economics of Reliability

Reliability Improvement through Asset Replacement

Aspects of Discounted Cash Flow Used in Capital Equipment Replacement Analysis

Estimating the Interest Rate Appropriate for discounting

Present-Value Calculations

The effects of Inflation in the Analysis

Calculating the Equivalent Annual Cost (EAC)

Economic Life of Capital Equipment

The “Classic” Economic Life Model

Before-and-After Tax Calculations

The Repair-vs-Replace Decision

Life-Cycle Costing

Technological Improvement

Group and individual exercises

Clinic: Hands-On Use of PC Software for Capital Equipment Replacement Analysis

Participants will solve pre-set problems

Effective Management of Maintenance Resources & Information

Effective Use of Maintenance Resources

Organizational Structure, Crew Sizes, Workshop Resource Requirements

Balancing Maintenance Costs against Plant Reliability

Establishing the optimal number of machines to have in a workshop

Resource Requirements Using Queuing Theory and Simulation

Utilization of Outside Resources

Lease-vs.-Buy Decision

Case studies including balancing maintenance cost and reliability in an electrical generating station, establishing optimal mix of machines to have in a steel mill maintenance workshop, establishing shift patterns and maintenance crew sizes in a petrochemical plant.