Maintenance - Roadmap to Reliability

Reasons why you need to attend this training
- LEARN how to start-up and organize the Maintenance pillar and understand the most important preparations needed to improve the reliability of industry’s assets and equipment.
- PROVIDE a crystal clear direction and roadmap for maintenance on how the highest reliability of your equipment and assets in your industry
- LEARN what support operators needs from Maintenance.
- LEARN the details on how to integrate RCM (Reliability-Centered Maintenance) into the higher Phases/ Steps of Planned Maintenance.
- Find out if TPM and RCM contradict or complement each other.
- DISCOVER how to reduce unplanned breakdowns in your plant.
- LEARN how to implement Planned Maintenance right the first time and avoid costly mistakes and seeing what works and not.
- LEARN how to prepare and develop the Maintenance “MASTER PLAN”.
- LEARN what it takes to implement Planned Maintenance right the first time.
- LEARN how your industry can save on cost on doing Maintenance
- FINALLY ask yourself, is my plant ready for the Planned Maintenance experience?
What this course is all about
This course covers a strategy for maintenance people to achieve a high reliability of their equipment and assets through the principles of Planned Maintenance Four Phases to Zero unplanned breakdown strategy.
- Phase 1 deals with Stabilizing MTBF, main activity involved here is restoration by establishing Equipment Basic Equipment Condition.
- Phase 2 deals with Addressing Equipment Weak- nesses in Design and addressing them to prolong the lifespan of parts.
- Phase 3 and 4 of Planned Maintenance deals with developing a Maintenance Tasks Selection Diagram in order to classify which parts will fall on the different maintenance tasks available. This is where Reliability Centered Maintenance can be used. Phase 4 if Planned Maintenance is about Predicting Failures through a system known as Condition-Based Maintenance and the use of Diagnostic tools to monitor condition of parts

Maintenance – Roadmap to Reliability Day 1
8:00 – 8:30 - Coffee and Registration
8:30 – 9:00 - Welcome and Introduction of resource speaker
                    - Take MRR Pre-post IQ Quiz
9:00 - 10:00 - Introduction : Changing The Maintenance Culture
                      - Domino Effect of Being Reactive
                      - Can Maintenance Really Eliminate Equipment Breakdowns and Failures 1000 - 1015 - Morning Break / Meals
1015 - 1200 - Module 1 : Maintenance – Roadmap to Reliability Overview
                      - Planned Maintenance Defined
                      - 4 Phases of Planned Maintenance
                      - The 2 sides of Failure
                      - The Concept of Planned Maintenance Activities
                      - MRR Preparatory Stage
                      - How Maintenance is Being Approached By Industries
                      - Having a Clear Concept on What Constitute a Breakdown and Not
                      - Knowing MTBF, MTTF and MTTR
                      - Understanding what MRR wants to achieve
1200 - 1300 - Lunch
1300 - 1500 - Module 2 : Phase 0 – MRR Preparatory Stage
                      - Understanding The Need for An Effective Maintenance Structure
                      - Establishing the Maintenance Vision and Mission
                      - Importance of Conducting Machine Ranking
                      - Developing a Master Plan for Maintenance
                      - MRR Phase 0 Details Step by Step Roadmap of Activities
1500 - 1515 - Afternoon Break / Meal
1500 - 1700 - Module 3 : Phase 1 - Stabilize MTBF - The Need To Restore and Address the Basics on Our Equipment
                     - 3 Basic Activities on Planned Maintenance Phase 1
                     - Maintenance Guidance and Support for Operators
                     - Function Loss and Function Reduction Breakdown
                     - What Phase 1 will Achieve
                     - 60 to 80% Reduction in Unplanned Breakdown
                     - Horizontal Replication of Phase 1 Activities
                     - Detailed Step by Step Roadmap of Activities for Phase 1
1700 - End of Day 1
Maintenance – Roadmap to Reliability Day 2
8:00 – 8:30 - Coffee and Recap of Day 1
0830 - 1000 - Module 4 : MRR Phase 2 Addressing Design Weakness
                      - Concept of Phase 2
                      - Every Equipment Has Its Weaknesses In Design
                      - How to Addressing Equipment Design Weaknesses
                      - Analytical and Problem Solving Techniques for Maintenance
                      - Investigating Equipment Failures Through Root Cause Failure Analysis
                      - Step by Step Detailed Roadmap of Activities for Phase 2
1000 - 1015 - Morning Break / Meals
1015 - 1200 - Understanding Different Types of Wear
                      - Perform Exercise on Wear
                      - Abrasive, Adhesive, Erosive, Fatigue and Corrosive Wear
                      - Understand How To Control These Types of Wear
                      - Take Quiz on Different Types of Wear
                      - Case Study on Phase 2
1200 - 1300 - Lunch
1300 - 1500 - Module 5 : MRR Phase 3 Periodically Restore Deterioration
                      - Common Belief on Maintenance
                      - Does All Parts Wear Out
                      - Understanding Infant, Random and Age Related Failures
                      - Understanding Reliability-Centered Maintenance
                      - Preparing the RCM Information Worksheet
                      - Understanding the RCM Decision Diagram or Algorithm
1500 - 1515 - Afternoon Break / Meal
1515 - 1700 - Hidden and Evident Failures
                      - Understanding the Consequences of Failure Environmental, Safety,
                        Operational and Non-Operational Consequences
                      - Failure Consequences Exercise
1700 - End of Day 2 Maintenance
Roadmap to Reliability Day 3
0800 - 1000 - Recap of Day 2
                      - Module 6 : PM Phase 4 Predict Equipment Lifetime
                      - Understanding the Concept of Predictive Maintenance
                      - P-F Curve Explained
                      - Integrating RCM into the TPM Planned Maintenance Structure
                      - Understanding the Different Maintenance Tasks Available
                      - Deriving the Maintenance Tasks for Equipment
                      - Phase 3 and 4 Roadmap of Activities
1000 - 1015 - Morning Break / Meals
1015 - 1200 - Understanding Reactive, Preventive, Predictive and Proactive
                        Maintenance
                      - MRR WORKSHOP 1 Workshop on Maintenance Tasks
1200 - 1300 - Lunch
1300 - 1400 - MRR WORKSHOP 2 : Planned Maintenance Board Game
1500 - 1515 - Afternoon Break / Meal
1515 - 1600 - Actual Case Study: JIPM Planned Maintenance Success Story
1600 - 1630 - Take Post Quiz on MRR
                      - Check Pre-Post Quiz on MRR
1630 - 1700 - Starting an Improvement Reliability
                      - Awarding of Certificates
                      - Summary and Closing
1700 - End of Seminar

Rolly, is a seasoned international reliability and mainte-nance consultant with 29 yrs of solid experience in the field.  He had been invited in different countries and have conducted reliability and maintenance trainings as well as consultation on United Arab Emirates, India, Malaysia, Indonesia, Thailand, Nigeria, China, Thailand, South Africa, Botswana, Bangladesh and Brunei. 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 Twelve Disciplines, Oil Contamination Control,  Maintenance Indices and KPI’s, Maintenance Management System and much more.  Rolly previously worked with Amkor Technology Phils., as a TPM Senior Engineer,  an industry engaged in the manufacture of IC products and spearheaded their TPM Planned Maintenance organization compose of maintenance managers and engineers. He was responsible for the dramatic reduction of unplanned breakdowns in their TPM Journey as well as RCM implementation on their Facilities AHU and as well as their sub-station equipment.  His last working experience at Lepanto Mining is where he started developing these maintenance trainings.  Rolly is currently working as an independent reliability and maintenance consultant and will be soon releasing his 2nd book  Maintenance – Roadmap to Reliability.

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