#1615 - Maintenance Practices for Improved Plant Profits
In today’s environment, process plants are interested in increasing profitability by
improving reliability and achieving maintenance excellence. To attain these ends, new
approaches and tools are being used. The purpose of this course is to introduce a model
for improving maintenance effectiveness and increasing plant reliability. In addition to
a framework, a review of some maintenance techniques and tools will be included.
Who Should Attend
Supervisors and managers assigned responsibility for maintenance cost and unit reliability.
Participants should have an understanding of their plant’s current performance
and opportunities for improvement.
This course is divided into three main sections, as described below.
This session introduces the concepts of maintenance excellence and the perspective of
what is happening in the maintenance world today. A framework for achieving World
Class Maintenance will be presented, including a discussion of some of the best
practices for achieving excellence in maintenance. The session will end with a
discussion of how equipment fails and what impact maintenance has on failure.
- Introduction: An overview of the course will be presented and
participant expectations elicited. Also, what is happening in maintenance today will be reviewed. A discussion will be held with
participants to understand their maintenance
organization and their strengths and areas for improvement.
- What Is Maintenance: Different types of maintenance and the effect they have on equipment reliability will be reviewed: how equipment fails and what influence maintenance has on equipment failure. Total Productive Maintenance (TPM) will be introduced, including the tasks plant personnel can undertake. A review of different maintenance organizations will be included.
- Maintenance Excellence: A framework for a World Class Maintenance Organization will be presented which will include guiding principles, key elements, Best Practices, and a process for changing a maintenance organization.
Participants will have an opportunity to score their organization against the framework.
- Equipment Failure Patterns: How equipment fails and the “bath-tub” curve will be reviewed. Also, how to prevent equipment failures and what effect maintenance has on equipment failure will be presented.
Participants will be asked to discuss how their equipment fails and if it matches traditional patterns.
This session introduces a model for achieving excellence in maintenance with a review of each model component. Such areas as overall philosophy, risk-based decision-making, and work scope justification will be discussed. Metrics will be introduced for stewarding performance and activities needed for continuous improvement.
- Maintenance Management Model: A model for conducting plant maintenance will be presented. The model is based on a proven model that has been successfully used to achieve maintenance excellence. This module establishes the basis for the subsequent modules that will explain the various model elements in more detail. Discussion will follow where
participants will discuss their plant maintenance model.
- Maintenance Objective Setting: This module will present the various business
plans needed for an effective maintenance organization, including examples.
Participants will have an opportunity to discuss the policies and plans their
organizations have in place.
- Work Selection: Procedures for screening work requests and how work should be
prioritized will be discussed. Risk-based decision-making will be included,
integrating different risk matrices. Also, cost benefit analysis will be reviewed and
how it can be used to prioritize work.
- Work Planning and Scheduling: The roles and responsibilities of planners and
schedulers are presented, plus the procedures for performing both activities. The
discussion will include the staffing and criteria for effective planning and what should
be included in an effective work plan. Also included will be some metrics for
- Work Execution: Different contracting approaches are presented along with the
objectives of work execution. An example roles and responsibilities list for
supervisors is included.
- Stewardship: This section covers the activities normally employed to ensure
maintenance objectives are achieved. Performance metrics are also reviewed with
target values for business, system, and functional indicators.
- Continuous R&M Improvement: Activities to improve reliability performance are
reviewed, including several techniques for performing failure analysis. When to do
and when not to do a failure analysis is discussed.
This session introduces a number of techniques and tools for maintenance
improvement. Specific tools that will be discussed are Reliability Centered
Maintenance, Life Cycle Cost Analysis, and various monitoring techniques. Human
reliability and its influence on plant operability will be reviewed.
- Life Cycle Cost Analysis: What LCCA is and the methodology for applying the
technique will be discussed. The time value of money and the timing for applying
LCCA will be presented. An example is included.
- Reliability Centered Maintenance: An introduction to RCM, including the history,
benefits, and procedure for performing an RCM analysis will be presented. As part
of the presentation, an example is included to help participants understand the work
process. The module ends with a discussion on how to implement the process.
- Monitoring Techniques: Two monitoring approaches that can be used to improve
equipment performance will be reviewed: condition-based techniques and analytical
tools. Various condition-based tools are discussed and the approaches for analyzing
equipment failure data are reviewed.
- Human Reliability: The cost of human reliability on a plant is presented and the
characteristics of what cause human unreliability. The emphasis is that human
reliability cannot be forgotten and must be considered in the design and engineering
of a plant and day-to-day operation.
- Wrap-up: A review of the expectations elicited at the initial session will be
reviewed and any follow-up to clarify the material presented.
Most of the modules will include discussion on what is happening at the
plants and how their operations compare to the material presented. Also, some
exercises will be included.
Course Duration – 3 days