#1600 - Achieving World Class Maintenance Performance

Course Objective

Upon completion of this management training course, attendees will be able to evaluate their plant’s maintenance practices and develop a program to achieve “world class” maintenance performance. They will:

Understand how their plant’s maintenance practices compare with industry leaders. In addition, they will be able to identify key improvement areas and understand the steps that are required to achieve the desired savings.

Understand the practices used by industry leaders to achieve successful T/As. They will learn the seven phases of T/A management and the actions necessary in each phase.
Be able to conduct work request justification reviews, which are based on the business principle of return on maintenance investment. They will have an understanding of how to develop risk scenarios reflecting realistic consequences and probabilities that can be used to establish the needed scope and timing of maintenance work.
Be able to understand the principles of Life Cycle Maintenance Management (LCMM). They will have an understanding of how to develop LCMM plans for their key equipment and the application of this information to the development of maintenance budgets.

Who Should Attend?

Supervisors and Managers who are assigned the following responsibilities:

Maintenance cost, equipment and unit reliability. Attendees should have an understanding of their plant’s current performance, maintenance practices, and opportunities for improvement.
T/A cost and unit performance. Attendees should have an understanding of their current T/A practices.

Course Description

This course is divided into four main sections:

Section 1 – Maintenance Practices That Improve Plant Profits

This section introduces the concepts of benchmarking maintenance performance against industry leaders. It focuses on changing maintenance philosophy and outlines top performer practices. A stepwise approach to improving maintenance performance is presented. The following topics are covered:

Strategy for maintenance excellence
Symptoms of poor performance
Competitive performance
Changing maintenance philosophy
Top performer practices
Achieving progress

Section 2 – Turnaround (T/A) Management

This section introduces the concepts associated with the successful planning and execution of major T/As. It presents milestones identifying the actions needed and their appropriate timing. The following topics are covered:

Strategic planning
Scope control
Budget development and control
Detailed planning
Contracting
Execution
Close out assessment

Section 3 – Work Request Justification

This section introduces the concept of risk based work justification. It presents the methodology for justifying the need, scope, and timing of maintenance work. The following topics are covered:

Organizational roles
“Required vs. discretionary”
Risk based decision making
Priority setting
Justifying work scope
Savings/cost analysis
Time value of money

Section 4 – Life Cycle Maintenance Management

This section introduces the concept behind Life Cycle Maintenance Management (LCMM). It presents a stepwise approach to develop LCMM Plans based on top performer practices. The following topics are covered:

Define areas of vulnerability
Identify critical components
Timing and consequence assessment
Assess timing and scope of maintenance intervention
LCMM for spared equipment
Managing LCMM data