Reliability-Centered Maintenance for Industries

This course will let you think differently on how you do maintenance.
One of the underlying assumptions of maintenance theory has always been that there is a fundamental cause and effect relation- ship between scheduled maintenance and operating reliability This assumption was based on the intuitive belief that because mechanical parts wears out, the reliability of the equipment is based on its operating age. It follows that the more often the item is overhauled the better protected it was against the likelihood of failure. Over the years, however, it was found out that many types of failures cannot be prevented no matter how intensive the maintenance activities. Extracted from the manuscript of Nowlan and Heap But the most valuable lessons learned by the Airline Industry is that maintenance is not about Preventing Failures but understanding & dealing with the consequences of failure and this is what a true and meaningful maintenance is all about. Almost every industry have some form of Preventive Maintenance where they scheduled their equipment for some re- placement and overhauling activities on a time-dominated pattern. But despite the very best  and noble efforts, a lot of unexpected problems, breakdowns and failures still  occur on the equipment and every single hard knock maintenance know and have  experience about this. Worst, operators of equip- ment complains, that Preventive Maintenance group had just made their equipment worst after performing their routing PM overhauling.  There is a detailed and thorough technical explanation behind this. Whilst, others think about maintenance as  transitioning from a Preventive to Predictive Maintenance, while some think it about transitioning from reactive to proactive maintenance. These people have been truly misinformed. No disrespect, but am not against Preventive Maintenance, but I’m against people who abuse the use of Preventive Maintenance and continuously add intrusive or force maintenance activities into the never ending list of PM activities to be done. In view of this, I would like to invite your key people on this one time event on "Reliability-Centered Maintenance" that  will provide each and every maintenance an indebt understanding on what maintenance is all about, what it can do and what it cannot do so that we can  grasp an understanding on how we can do maintenance on our plants.  This  course will make you think differently on how you perform your  maintenance.

RCM Course Objectives:

• Provide a deeper understanding on what it takes for our maintenance to be most effective and efficient.
• Realize that the feasibility of performing maintenance tasks will always be based upon the consequences of the failure itself.
• Know when to use the different maintenance tasks with the aid of a decision diagram.
• Learn why even the most noblest efforts on Preventive Maintenance cannot prevent failures from occurring.
• Learn how to integrate RCM in our maintenance activities.

 RCM Course Modules: (Duration – 3 days)

 Module 1: A Typical Reactive Maintenance Culture

• Problems facing our industry
• Domino effect of being reactive
• A structured maintenance system

 Module 2: Introduction to Reliability-Centered Maintenance 

• Maintenance defined
• Common belief on maintenance
• RCM origin and evolvement in airline industries
• Understanding the six failure patterns
• Brief history and definition of RCM
• Strengths of RCM and TPM respectively

Module 3: RCM Information Worksheet (FMEA)

• How to prepare functions
• Determining the functional failures, failure modes and failure effects
• Perform RCM exercises on FMEA

Module 4:  Understanding the Consequences of Failure

• Hidden and evident failures
• Safety and environmental consequences
• Operational consequences
• Non-operational consequences
• Perform exercises on failure consequences

 Module 5: Understanding the Different Maintenance Tasks

• Preventive maintenance tasks
• Condition-based maintenance tasks
• Failure finding inspection and functionality check
• Run to fail
• Redesign or modification
• Perform exercises on the different maintenance tasks

Module 6: RCM Decision Worksheet

• RCM decision worksheet form
• Maintenance tasks selection diagram
• Applying the different maintenance tasks and documenting the RCM process

Module 7: Maintenance Tasks and RCM Workshop

• Perform exercises on the different maintenance tasks
• Perform RCM workshop
• Team Presentation on RCM 

 Module 8: RCM Facilitation

• Composition of RCM teams
• Tips on Performing RCM

 Module 9: Applying the RCM roadmap

• RCM eight question are we ready for the change
• Benefits of adopting RCM strategy in our plant

Lessons on Reliability-Centered Maintenance
Closing Remarks and Awarding of Certificates

Rolly, is a seasoned international reliability and maintenance consultant with 29 yrs of solid experience in the field.  He had been invited in different countries and have conducted reliability and maintenance trainings in United Arab Emirates, India,  Malaysia, Indonesia, Nigeria, Bangladesh, South Africa, China, Thailand and recently in Bostwana.  His portfolio of maintenance trainings include Maintenance Management courses on TPM, Lubrication, Tribology, Condition-Based Maintenance, RCM, RCFA, Planned Maintenance, World Class Maintenance Management, The 12 Disciplines, Oil Contamination Control,  Maintenance Indices and KPI’s, Maintenance Management Strategies and much more.  Rolly previously worked with Amkor Technology Philippines, as a TPM Senior Engineer,  an industry engaged in the manufacture of Integrated Circuit products and spearheaded their Planned Maintenance organization com-pose of maintenance managers and engineers. He was also responsible for the dramatic reduction of unplanned breakdowns in their TPM Journey as well as RCM implementation on their Facilities AHU units and as well as their substation equipment.  Rolly is currently working as an independent reliability and maintenance consultant.  Rolly had written 2 books on maintenance on World Class Maintenance Management - The Twelve Disciplines and his most recent one which is Maintenance - Roadmap to Reliability.

For training inquiries contact the following:
[email protected]
website: www.rsareliability.com
Contact 09194511708