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Optimizing Equipment Maintenance & Replacement Decisions » MA11

Optimizing Equipment Maintenance & Replacement Decisions

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14 Nov - 18 Nov, 2022Live Online5 Days$2150Register
19 Feb - 23 Feb, 2023Live Online5 Days$2250Register
24 Apr - 28 Apr, 2023Live Online5 Days$2250Register
31 Jul - 04 Aug, 2023Live Online5 Days$2250Register
22 Oct - 26 Oct, 2023Live Online10 Days$4495Register
17 Oct - 21 Oct, 2022Lisbon5 Days$5695Register
18 Dec - 29 Dec, 2022Dubai10 Days$6750Register
20 Feb - 24 Feb, 2023Abu Dhabi 5 Days$4950Register
18 Jun - 22 Jun, 2023Doha5 Days$4950Register
04 Sep - 15 Sep, 2023Toronto 10 Days$9850Register
13 Nov - 24 Nov, 2023Dubai10 Days$8775Register

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Course Overview

This Optimizing Equipment Maintenance & Replacement Decisions training programme is beneficial for you if your answer is YES to any of the questions below:

  • Are you in a need to optimize your requirements for an emergency spare?
  • Do you know the ways to decide the optimum asset life?
  • Before the planned replacement, is your equipment failing?
  • Is non-availability of the spare parts, stopping you to implement the maintenance tasks?
  • Are you facing difficulties in justifying the economics of asset replacement?
  • Are you facing difficulties in realizing the benefits of investing in CBM tools and methods?
  • Are you struggling to predict your equipment breakdown even though you have lots of data available form oil analyses?
  • Are you struggling in deciding whether to replace or rebuild your equipment to reduce the life cycle costs?

Who Should Attend?

Personnel who can attend this Optimizing Equipment Maintenance & Replacement Decisions course are:

  • Professionals of plant operations
  • Facility professionals
  • Engineers
  • Maintenance professionals
  • Reliability professionals who are involved in the procedures of managing and maintaining the physical equipment assets of a facility or plant

Course Objectives:

The Optimizing Equipment Maintenance & Replacement Decisions Course Objectives are summarized below:

  • The principal concern of this training programme is based on the concepts of making the most optimal and best decision
  • To provide the maintenance managers, schedulers, planners and engineers with the ways of selecting the appropriate analytical tools for their decision making primarily for the maintenance purposes
  • To bring forward the crucial decision-making topics that can bring a notable difference to the in-service time of equipment, to the costs relevant to maintenance and the asset utilization optimization
  • To emphasize the techniques of optimization
  • To demonstrate the growing focus of industrial safety and the abundance of safety-relevant litigation

Course Outline:

Module I

  • Introduction to Reliability concepts and Physical Asset Management
  • Overview: Moving From Maintenance Management to Physical Asset Management
  • Physical asset management: The challenges
  • The concept of The maintenance excellence pyramid
  • Total Productive Maintenance: Overview
  • Reliability Centered Maintenance: Overview
  • Replacement Decisions and optimizing maintenance
  • The concept of Reliability Improvement through Preventive Maintenance
  • Component Failure Data: Analysis
  • Density Function: The Probability
  • Reliability Function: Overview
  • Understanding the Weibull Density
  • Understanding the concept of Infant Mortality
  • Bath Tub Curve: Definition and introduction
  • The Concept of Exercise in Analyzing Component Failure Data Using the Weibull Distribution
  • Weibull Parameters: The Estimation
  • Median Rank Tables: The usage
  • The concept of Dealing with Censored Data, the 3-Parameter Weibull, and the Kolmogorov-Smirnov Test
  • Multiply Censored Group Data, and Upper-End Censoring
  • Location Parameter in the Weibull Distribution: Estimation
  • Goodness-of-Fit of the Distribution: Checking

Module II

  • Introduction to Spare Parts Replacements and Preventive Maintenance
  • The concept of Reliability Improvement through Preventive Maintenance
  • An overview and the concept of Component Replacement Procedures including Glasser’s Graph
  • Policies of block replacement
  • Replacement Policy: age-based
  • Concept of setting policies based on cost minimization, safety constraints and the availability maximization
  • Repairable systems: The concept
  • Component Preventive Replacement: The case studies
  • Inclusion of compressor valves and centrifuges, pumps, boiler plant, sugar feeds bearings
  • Provisioning of the spare parts
  • Fast-moving spares: concept
  • The concept of Emergency spares
  • Spares provisioning: Case studies
  • Inclusion of cylinder heads, repairable conveyor electric motors, utility transformers, and, line replaceable units (LRUs)
  • Description of the Group and individual exercises
  • The concept of Hands-On Use of PC Software for Preventive Replacement Strategies: Clinic solution of pre-set problems

Module III

  • Inspection and monitoring of the machine health
  • The concept of Reliability Improvement through Inspection
  • The overview: Depth for equipment in continuous operation and inspection frequency
  • The concept of Inspection Intervals to Maximize Profit
  • Equipment Availability: Maximizing
  • An Overview: Inspection Intervals for Equipment Used in Emergency Situations (e.g. protective devices)
  • The Description and Overview of the Case studies including oil and gas field equipment such as pressure safety valves (for protective devices)
  • Procedures of health monitoring
  • The concept of Proportional Hazards Modelling
  • Analysis Programs for Spectroscopic Oil
  • Condition-Based Maintenance Procedures: Optimization
  • CBM optimization: Role of software
  • Inclusion of case studies for food procession industry (vibration monitoring), pulp and paper and shipping equipment such as compressors (vibration monitoring), turbines in an electrical generating station (pressure measurements) and diesel engines (oil analysis)

Module IV

  • Reliability Economics
  • The concept of Reliability Improvement through Asset Replacement
  • The Essential Aspects of Discounted Cash Flow Used in Capital Equipment Replacement Analysis
  • Interest Rate Appropriate for discounting: The estimation
  • Present-Value Calculations: An overview
  • Analysis: The effects of inflation
  • Equivalent Annual Cost (EAC): Calculation
  • Capital Equipment: The economic life
  • Economic Life Model: The classic model
  • The concept of Before-and-After Tax Calculations
  • Understanding The Repair-vs-Replace Decision
  • Life-Cycle Costing: An overview
  • Technological Improvement: Introduction
  • Description of the Group and individual exercises

Module V

  • Maintenance Resources & Information: Effective management
  • Maintenance Resources: The effective usage
  • The concept of the Organizational Structure, Crew Sizes, Workshop Resource Requirements
  • Maintenance Costs against Plant Reliability: The concept of balancing
  • Optimal number of machines to have in a workshop: The process of establishment
  • Queuing Theory and Simulation: resource requirements
  • Outside Resources: The utilization
  • Understanding the Lease-vs.-Buy Decision
  • Inclusion of balancing maintenance cost and reliability in an electrical generating station, establishing shift patterns and maintenance crew sizes in a petrochemical plant, establishing an optimal mix of machines to have in a steel mill maintenance workshop
  • Management Information Systems: The maintenance process
  • Auditing a CMMS: The methodology
  • Summary

General Notes

  • All our courses can be facilitated as Customized In-House Training course.
  • Course duration is flexible and the contents can be modified to fit any number of days.
  • As for Open Enrolment Courses, we offer our clients the flexibility to chose the location, date, and time and our team of experts who are spread around the globe will assist in facilitating the course.
  • The course fee includes facilitation, training materials, 2 coffee breaks, buffet lunch and a Certificate of successful completion of Training.
  • FREE Consultation and Coaching provided during and after the course.

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