Course Overview

What’s the difference between preventive maintenance and predictive maintenance? This program is designed for an in-depth understanding of preventive and predictive maintenance methodologies.

This fundamental course will prepare aspiring professionals from engineering, maintenance, projects and operations to get maximum out of the investments in assets. This program is designed for senior operators, supervisors, engineers and managers, inspectors and purchase staff members.

It covers a practical aspect of maintenance concepts, approaches, practical methods for managing a large number of variety of assets spanning multi-disciplines for safe and reliable operations and business performance.

This Zoe training program is designed to provide valuable information on machine predictive maintenance techniques as a tool for quickly identifying and correcting the root causes of machinery problems, achieving precise operation, and improving machinery performance.

Special importance is given to troubleshooting, data interpretation, health assessment, and maintenance decision-making. This training course is designed to train individuals who are interested in a career in maintenance engineering and management.

Course Objectives

The training program will incorporate instructions, guidelines and orientation to:

• Understanding engineering issues in managing an effective preventive and predictive maintenance program
• Learn to apply practically to field for augmenting maintenance performance
• Understand the importance of quality control requirements during fabrication and erection
• Understanding common types of maintenance, relative advantages and disadvantages
• Classifying and developing asset database
• Modelling costs, optimizing resource applications
• Overview of vibration analysis, phase, FFT and spectrum analysis

Training Methodology

This collaborative “Implementing Effective Preventive and Predictive Maintenance Course” will include the following training methods:

• Lectures
• Seminars & Presentations
• Group Discussions
• Assignments
• Case Studies & Functional Exercises

Zoe Talent Solutions follows the ‘Do-Review-Learn-Apply’ model.

Organisational Benefits

Companies who appoint their employees to participate in this “Implementing Effective Preventive & Predictive Maintenance Course” can benefit in the following ways:

• Manage the effectiveness of a maintenance program
• Technicians, operators, supervisor’s and engineers can successfully design and manage maintenance strategies for all types of assets

Personal Benefits

Individuals who join in this “Implementing Effective Preventive and Predictive Maintenance Course” can gain from it in the following ways:

• Design and develop an optimal preventive plan
• Implement predictive techniques and modern tools for optimizing performance
• Calculate maintenance costs

Who Should Attend?

This Implementing Effective Preventive and Predictive Maintenance Course would be suitable for:

Supervisors, Engineers and Technical Supervisory Personnel, Personnel responsible for implementing preventive and predictive management programs

Course Outline

Module 1:  Basics and Maintenance Overview

• Introductory Test / Evaluation

• What is maintenance, types and importance for an organization?

• Basic overview, the importance of logs and technical history
• Asset life cycle management overview and strategy for various stages
• Objectives, costs and modelling

• Introduction to maintenance management systems:

• Work centre’s and scheduling
• Understanding parts, part list, equipment drawings
• Role of maintenance for the organization’s profitability
• Understanding quality requirements and the importance of inspection

• Developing Inspection Plans and procedures for equipment’s

CBM – Conditioned Based Maintenance

• Life Cycle and Normal Wear and Tear
  • Overview of the role of condition monitoring

• World Class Maintenance

• Types of maintenance
• Corrective maintenance
• Preventive maintenance
• Proactive maintenance

Module 2: Maintenance Management Systems

• Maintenance information system

• Manufacturer recommendations in equipment manuals
• Use of right and recommended tools
• Basics of CMMS and terminology

• Prevention of equipment failure:

• Identifying failures and preventive care
• Right operations and care for equipment
• Toolbox talks and their role in care for equipment
• Spares parts, inventory management foundations
• The root cause analysis basics through examples

Predictive Maintenance Tools

• Vibration Measurement and analysis

• Measuring Vibration
• Amplitude
• Displacement
• Velocity
• Acceleration
• Frequency
• Phase
• Vibration Analysis
• Complex Vibration
• Machinery Vibration Severity
• Velocity RMS
• High-Frequency Detection System
• Components of a Signal
• Vibration Transducers
• Overall and Spectral Vibration
• Monitoring Point Location and Transducer Mounting
• Engineering requirements for reliable performance
• Vibration analysis basics
• Phase / spectrum / FFT analysis and their importance

Module 3:  Preventive Care & Systems, RCM Overview

• Basics of thermal cycling and fatigue damage to assets
• Reliability centred maintenance overview (RCM)
• Thermography and application for preventive care
• Risk-based maintenance method
• Review of lessons learned and activity

Other Predictive Maintenance Techniques

• Thermography
• Temperature Measurements
• Ways of Monitoring Temperature

• Infrared Thermal Imaging
• Samples

• Sensitivities and Symptom Masking
• Fault Detection Capability

Lubricant Monitoring

• Oil and Wear Debris Analysis

• Oil Analysis (Tribology)

• Sources of Wear Debris
• Fluid Monitoring/Contamination Control
• Wear in Lubricated Systems
• Wear Debris – Transport / Supervising, Monitoring Efficiency and Analysis
• Lubricant Properties and Oil Analysis

Module 4: Failure Detection and Analysis:

• Equipment failure and damage modes

• How failure occur, understanding modes of failures
• Precautions
• Total productive maintenance
• Designing a maintenance management program
• Monitoring effectiveness of maintenance systems
• Restoration work management
• Task list development and estimation
• Action plan for field assets

Module 5: Modern Maintenance Management Tools

• Static assets planning upkeep programs
• Failure modes and effect analysis
• Predictive maintenance planning
• Resources for improving knowledge
• Maintenance costing
• How to prevent the accumulation of old spares?
• Cost savings in managing spares effectively
• Understanding interchangeability and optimizing spares procurement
• Case study & discussions
• Evaluation test