World Class Maintenance Management – The 12 Disciplines

WCM Course Overview: Being World Class means the ability to compete anywhere in the world. World Class Maintenance Management means the art and science of managing our maintenance resources performed by best in class industries from around the world. But in most industries, is it really possible to manage maintenance or the pressure over maintenance is managing us for a long time?  This course provides a discussion on how failure occurs in three patterns and why most of our efforts on maintenance only address one pattern which is the wear out failures. This course also covers the twelve maintenance disciplines is in order to improve equipment reliability. These twelve disciplines are categorized into three parts, the basics, the strategies and the advance discipline.  Know what disciplines most world-class industries are adopting.

Course Objective

• Understand the need for an effective and World Class Maintenance Management structure in our plant
• Understand the importance of establishing the basics of maintenance before adopting any improvement strategy
• Understand when to effectively use each of the different maintenance strategies in order to fully improve the equipment reliability
• Develop a Corporate Strategy for maintenance function
• Provide a basic understanding on the 12 Disciplines of Maintenance Management and understand the real focus of a true and meaningful Maintenance Structure
• Understand the real focus of a true and meaningful maintenance structure
• Learn what it takes to achieve a World Class Maintenance stage in your industry

Training Package
• Morning / Afternoon meals and Lunch
• Complete Handouts on WCM course
• Selected Articles on WCM
• Exercises and Handouts on WCM
• CD Softcopy of WCM Training in powerpoint
• Certificate of Attendance
• World Class Maintenance Book – 314 pages
• Maintenance – Roadmap to Reliability book

Who should attend
• Maintenance Managers
• Facilities and Utilities Managers
• Preventive/Predictive Maintenance Group
• Reliability Engineers and Managers
• Operations and Production Managers
• Management and Decision Makers
• Continuous Improvement Groups
• People in charge of their assets
• CMMS and Spare Parts Group
• People in charge of asset management
• Maintenance Planners, CMMS Groups

WCM Program Day 1 : Morning Session
Module 1: Understanding Equipment Failures
• The Truth About Machinery and Equipment
• Is It Really Possible to Eliminate Failures and Breakdowns on our Equipment
• What Maintenance is All About
• Common Belief on Maintenance – Does All Parts Eventually Wear Out
• What Stanley Nowlan and Howard Heap Discovered about Maintenance
• Limitations of Preventive Maintenance
• Understanding What Maintenance Can and Cannot Do
• Understanding Infant Mortality, Random and Age-Related Failures
• 6 Types of Failure Patterns
• Classification of Failures – Hidden and Evident Failures
• Types of Failures – Function Loss and Function Reduction Failures
• Occurrences of Failures – Sporadic and Chronic Failures

WCM Program Day 1 : Afternoon Session
Module 2 : Changing The Culture from Reactive to Proactive
• Reactive and Proactive Maintenance Explained
• Flowchart of a Reactive Maintenance Environment
• Learning the Correct Paradigm on Maintenance

Module 3 : Understanding World Class Maintenance Management
• World Class Maintenance Management Explained
• 12 Disciplines of Maintenance - Basics, Intermediate and Advance Discipline

Module 4 : Basic Discipline
• Discipline 1 : The Need for Training and Skills on Maintenance
- Training and Skills Assessment
- Steps to improve your current training needs
- Reflections and Learning’s from the first discipline
• Discipline 2 : Measurements and Maintenance KPI’s
- Most Common Mean Time Indicators
- Understanding Mean Time Between Failure (MTBF)
- Understanding Mean Time to Failure (MTTF)
- Setting Maintenance Goals and KPI
- Reflections and Learning’s from the 2nd Discipline

WCM Program Day 2 : Morning Session

Continuation on Module 4 : Basic Discipline
• Discipline 3 : The Need for Autonomous Maintenance
- Why Autonomous Maintenance is Important
- Autonomous Maintenance Basic Concept
- Maintenance Guidance and Support for Autonomous Maintenance
• Discipline 4 : Addressing Basic Equipment Condition
- Importance of Going Back to the Basics
- Cleaning, Proper Lubrication and Tightening of Bolts
- Role of Operators in Establishing Basic Equipment Condition
• Discipline 5 : Addressing Basic Equipment Condition
- Preventive Maintenance Definition and Objective
- What Preventive Maintenance Activities Includes
- Feasibility of Using Preventive Maintenance for Age-Related Failures
- Survey of Top 10 Problems on Preventive Maintenance

WCM Program Day 2 : Afternoon Session
Module 5 : Maintenance Management Strategies
• Discipline 6 : Lubrication Strategy and Management
- Function of oil and its composition
- What cause oil to breakdown
- Understanding how contamination occurs
- Our Belief on Contamination and Contamination Control Awareness
- Absolute and Nominal Filtration
- Filtration Efficiency and Beta Rating of Filters
- Oil Analysis – Level 1 Testing Oil’s Health and Cleanliness
- How to remove contaminants from oil
• Discipline 7: Understanding Life Cycle Management
- Concept of Life Cycle Costing
- Why the study of Life Cycle Costing is important
• Discipline 8: Spare Parts Management
- Spare Parts Management Explained
- Importance of Physical Inventory and Systems Inventory
- Problems and Issues on Spare Parts
- Importance of having a Spare Parts Management Strategy

WCM Program Day 3 : Morning Session
Continuation on Module 5 : Maintenance Management Strategies
• Discipline 9: Root Cause Failure Analysis
- Root Cause Failure Analysis Defined
- Evidence – The Lifeblood of any Root Cause Failure Analysis
- Difference between Failure Analysis RCA and RCFA
- Levels of Root Cause – Physical Cause, Human Cause and Latent Cause
- RCFA Case Study – Pump Failures
- Reflections and learning’s from the 9th Discipline
• Discipline 10: Reliability Strategies
- Understanding Reactive, Preventive, Predictive & Proactive Maintenance
- Concept of Reliability-Centered Maintenance
- How RCM is being Performed
- Comparing TPM and RCM and what both of them believes
- Reflections and learning’s from the tenth Discipline

WCM Program Day 3 : Afternoon Session
Module 6: Maintenance Management Advance Discipline
• Discipline 11: Understanding Condition Based Maintenance
- Predictive Maintenance Defined
- Understanding the P-F Interval
- Potential and Functional Failure
- Importance of determining Potential Failures
• Discipline 12: Computerized Maintenance Management Software
- Purpose of CMMS
- Application of CMMS
- Role of CMMS in Maintenance Management
- Considerations in selecting CMMS

Module 7: How to Apply the Twelve Disciplines of Maintenance
• Determine where your maintenance is right now
• Understand where you want to go
• Understand how will you go there
• Determine if you have finally arrived

Module 8: Learning’s from the 12 Discipline
• Closing Remarks on World Class Maintenance

For training inquiries and discounted costs kindly email the following
Angie Tibayan or contact 09998813762 or 09209688346
email: [email protected]
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