Training Associates

UNDERSTANDING PREVENTIVE AND PREDICTIVE MAINTENANCE WITH MODERN CONDITION MONITORING TECHNIQUES & TOOLS
Date:19th & 20th September 2019 Venue: Vistana Hotel Penang

Who Should Attend:This course has been designed for those who, because of their work is required to assist in the implementation of Preventive and Predictive Maintenance. These include the Production Managers, Maintenance Managers, Plant Managers, Engineer, Technicians, Executive and supervisor.

Course Objectives
Maintain the production equipment and plant utility systems equipment as close to Optimal near-new condition as possible and have all equipment ready to start up and run with no unplanned downtimes.

Maintain the production equipment and plant utility systems equipment in the best possible operating condition for the purpose of producing quality manufactured goods while the machines are in service.

Complete all PM and PdM work on a regularly scheduled basis without exceeding the "Point of Diminishing Returns on Investment" for the labor, tools and materials required to perform the work.

Day One
SESSION 1 – INTRODUCTION
1. Introduction to PPM
2. Definition of PPM
3. The History and Approaches towards Equipment Maintenance
4. The Introduction of Reliability Centered Maintenance (RCM)

SESSION 2 – THE APPROACH
Activities of Preventive and Predictive Maintenance:
1. Focused Improvement Kaizen Activities
2 Self Maintenance Activities
3 Planned Maintenance Activities
4 Technical Training for Technicians and Operators
5 Quality Maintenance Activities
6 Office 5S/TPM Activities
7 Safety and Environmental Management

SESSION 2 – THE APPROACH
Plant and Equipment Effectiveness Measurement System
1. Measuring Equipment Available
2. Measuring Equipment Performance Rate
3. Measuring Equipment Quality Rate
4. Measuring Total Effectiveness

Action Learning Exercise 1.
OEE Exercise to Understand OEE Application

SESSION 3 – ATTACKING THE “SMALL-GANGSTERs”TM
Definition of Self Maintenance As the First-line
Defence in Predictive Maintenance
Characteristics of Self Maintenance
1 Implementing Self Maintenance in Seven Steps:
 Clean & Continuous Inspection through 5S
 Eliminate Problem Sources & Hard-to-get places
 Develop Cleaning & Lubricating Standards
 Conduct General Inspection to Find & Correct Slight Abnormalities
through Tagging
 Develop Check-sheets & Conduct Autonomous Inspections
 Carry out Visual Maintenance Management
 Carry out Consistent Autonomous Management

Action Learning Exercise 2.
Red Tag Tagging Exercise to Expose Visual & Obvious and Difficult-to-find Problems or Potential Problems.
Day Two
SESSION 4 – PREVENTIVE MAINTENANCE
1. Standardization of Maintenance Activities
• Types of Standards
• Maintenance Standards
• Revision Standards

2. Maintenance Planning & Scheduling
• Analysing Equipment Breakdowns and MTBF
• The LEAN Equipment Maintenance Model
• Preparing Annual PM / Pdm Plans
• Preparing and Finalizing Monthly Maintenance Plans and Scheduling
Weekly PM/Pdm Activities.
• Managing Job Backlogs and Improvement
• Increase Maintenance Efficiency by Improving Maintainability (MTTR)
Action Learning Exercise 3.
Preventive Maintenance Work Schedule Design &
Development Exercise
3. Keeping and Using Maintenance Records
• Why Keep Maintenance Records
• The Flow of Maintenance Records
• Types of Maintenance Records
• Computerization of Maintenance (CMS)

4. Spare Parts Control
- Purpose of Spare Parts
- Classification of Maintenance Materials
- Ordering Methods
- Selecting Permanent Stock
- Establishing Order Points and Quantities

5. Small Group Improvement Team to Reduce Total Equipment Losses
- SGA Structure
- Improving Availability through MTBF and MTTR Management
- Reducing Equipment Set-up Losses through SMED

SESSION 5 – PREDICTIVE & MACHINE DIAGNOSTIC TECHNIQUES
1. Predictive Maintenance and Machine Diagnostic Techniques
2. The Need for Predictive Maintenance
3. Machine Diagnostic Techniques
4. Application and Aims of Predictive Maintenance
5. Principles in Condition Monitoring
6. Vibration Monitoring Methods(Portable Vibration Meters)
7. Ultrasonic Techniques (Using Engineering Stethoscope)
8. Oil Diagnostic Techniques
9. Temperature Monitoring and Diagnostic Techniques
Action Learning Exercise 4.
Trend Charting