Course Outline

Day 1: Objectives of Maintenance

·         What Is Maintenance? – A comprehensive definition of maintenance and its importance in operational sustainability.

·         Evolution of Maintenance – How maintenance strategies have evolved over time.

·       Challenges Facing Maintenance – Common challenges in maintenance management and ways to overcome them.

·    Types of Maintenance – A detailed overview of different maintenance strategies, such as corrective, preventive, and predictive maintenance.

·    classification of Roles in Maintenance – Roles and responsibilities of individuals within a maintenance team.

·      Customer Service in Maintenance – The importance of delivering high-quality maintenance service and its impact on customer satisfaction.

Day 2: The Work Order System

·   Purpose of the Work Order System – Understanding the key functions of a work order system in managing maintenance tasks.

·   information Collected on a Work Order – What information should be gathered and recorded during the maintenance process?

·  Job Estimating Methods – Approaches to estimating the time and resources required to complete maintenance tasks.

 ·  Prioritizing Maintenance Work – How to prioritize tasks effectively, balancing routine and urgent maintenance needs.

Day 3-4: Preventive Maintenance (PM)

·         Understanding Preventive Maintenance (PM) – The importance of preventive maintenance in reducing downtime and prolonging equipment lifespan.

·     Implementing a PM Program – How to create and implement an effective preventive maintenance program.

·       Establishing Scheduling for Preventive Maintenance – Developing a systematic approach for scheduling preventive maintenance tasks.

·         Breaking a Facility into Logical Parts – How to segment a facility for better organization and easier maintenance management.

·         Developing Equipment Lists – Creating and maintaining a list of all equipment requiring preventive maintenance.

·     Writing PMs (Preventive Maintenance Tasks) – How to create detailed and effective preventive maintenance task descriptions.

·         Developing Equipment Manuals – The role of comprehensive equipment manuals in maintenance planning.

 ·     Setting Up Inventory – How to organize and manage an inventory of spare parts and materials.

Day 5:  Planning and Scheduling Major Maintenance WOs and Shutdowns

 ·      Planning and Scheduling – Techniques for planning and scheduling major maintenance work orders and shutdowns.

·    Work Breakdown Structure (WBS) – Breaking down major maintenance tasks into manageable components.

·         Critical Path Method (CPM) – Using the Critical Path Method to ensure that all tasks are completed on time and resources are optimized.

Day 6: Resource Scheduling and Leveling, Life Cycle Cost of Equipment

   ·        Capital Budgeting – Understanding how to allocate financial resources for maintenance and equipment management.

·    Accounting Rate of Return (ARR) – Applying the ARR method to assess maintenance-related investments.

·    Payback Method – Using the payback method to evaluate the profitability of maintenance investments.

·     Net Present Value (NPV) – Calculating the NPV of maintenance projects to determine their financial feasibility.

·      Replacement Analysis of Equipment – Conducting a cost-benefit analysis for replacing aging or obsolete equipment.

Day 7: Planning and Controlling Maintenance Materials

 ·        Inventory Costs – Managing inventory costs related to maintenance supplies and parts.

·         Considerations in Inventory Decisions – Factors to consider when making decisions about ordering and stocking maintenance materials.

·         Economic Order Quantity (EOQ) – Using the EOQ formula to determine the optimal order quantity for inventory management.

·         Total Material Cost – Calculating and managing the overall cost of maintenance materials.

·         When to Order – Determining the best time to order materials based on usage patterns and inventory levels.

Day 8: Safety in Maintenance

 ·    Myths About Safety – Debunking common misconceptions about safety in maintenance operations.

·    Accidents and Injuries – Understanding the common causes of accidents and injuries in the maintenance process.

·  Unsafe Acts and Unsafe Conditions – Identifying unsafe practices and conditions that can lead to accidents.

·       Cost of Accidents – Estimating the direct and indirect costs of accidents and their impact on operations.

·      Safety Audits – How to conduct safety audits to ensure that the workplace is compliant with safety standards and regulations.

Day 9-10: Controlling Maintenance Work

 ·  Measuring Performance – Using performance metrics to assess the effectiveness of maintenance operations.

·   Sources of Data – Identifying sources of data and how to use this data for decision-making.

·         Backlog Indices – Managing maintenance backlogs and how to address pending tasks.

·         Schedule Compliance – Ensuring maintenance tasks are completed within the scheduled timeframes.

·         PM and Emergency Indices – Measuring the effectiveness of both preventive maintenance and emergency maintenance tasks.

·         Productivity Indicators – Key indicators used to measure the productivity of maintenance teams.