Predictive and Proactive Maintenance Techniques

Course details

Course Objective
At the end of this course participants will have:

• An understanding of a range of Predictive Maintenance Technologies
• Knowledge of the potential contribution of each these technologies to maintenance efficiency
• Guidelines indicating how these technologies can interact with and support each other
• Hints and Tips for practical application of these technologies so as to achieve the best results
• A practical approach to developing an action plan to utilize these technologies in their own areas of responsibility, fitting them into the overall maintenance strategy, and measuring benefits

 
Key Benefits
The knowledge gained in this course will:

• Enable the delegate to develop a proactive maintenance regime within the organization.
• Give the delegate confidence to carry out failure analyses thereby avoiding repetitive failures.
• Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service.

Who should attend?
This course is directed towards Supervisors, Team Leaders and Managers in Maintenance, Engineering and Production.
 
Program Contents:

• Maintenance introduction
• Types of maintenance
• Predictive maintenance. Overview of the Predictive Maintenance philosophy and
• Major predictive Maintenance technologies
• CBM methodology & management, Introduction to CBM tools & techniques
• Fault finding techniques
• Overview of Condition Monitoring Technologies:
• Vibration Monitoring
• Thermography
• Ultrasonic
• Non Destructive Testing Technologies

Executing a Maintenance and Equipment Audit Before Starting Preventive/ Predictive Maintenance (P/PdM)

• Determine your current maintenance productivity
• Establish your current equipment condition and equipment performance (baseline)
• Determine the need for preventive maintenance (PM) and predictive maintenance (PdM)
• Calculate costs and benefits of P/PdM

Determining the Right PM System for Your Plant

• Different types of PM
• PM organization and staffing

PM Techniques

• How to determine PM requirements for your equipment
• Equipment cleaning and lubrication
• Equipment inspections, adjustments, and servicing

How to Develop and Install a Good PM System

• The 10-step PM installation program
• How to keep an effective and useful equipment history
• PM work orders/PM checklists/PM reports

How to Plan and Schedule PM and Measure PM Results

• Determining PM frequencies and how to schedule PM
• Time-based or usage-based scheduling
• How to measure PM effectiveness and results
• How to measure and analyze downtime and downtime trends

Predictive Maintenance Techniques, Applications, and Instrumentation

• Elements of PdM (mechanical and electrical)
• Equipment condition monitoring
• Predicting potential equipment breakdowns or expensive repairs

Specific PdM Techniques and Applications

• Vibration analysis/monitoring
• Shock pulse method
• Spectrographic oil analysis
• Ferrographic particle analysis
• Thermography/temperature measurement
• Non-destructive testing (NDT)
• Ultrasonic testing and more

Getting Organized for PdM

• Planning for PdM; the preparatory steps
• Starting with a PdM pilot program
• Scheduling PdM
• Combining PdM with PM for greatest overall effect and least cost
• Organizational requirements

Measuring Results of PdM

• PdM database/data collection
• Costs of PdM (equipment/instruments, labor, and services)
• How to determine PdM benefits and return on investment (ROI)
• Decision factors for in-house vs. contracted PdM

Components of a Well-organized P/PdM Program

• Equipment inventory/numbering system
• Spare parts inventory/forecast
• Sequence of tasks (PM and PdM routes)
• Equipment and maintenance performance indicators and trends

Combining Planned Maintenance, PM, PdM, and TPM for Best Overall Results at the Least Costs

• Custom-making your maintenance system based on your equipment, plant location(s), and plant size
• Selling your solution to management (and getting the budget and management commitment)
• Phased installation for guaranteed results

 
  Updated on 18 September, 2019