Reliability and Maintenance Courses

Text Box: This course covers a wealth of information on the need to implement lubrication strategy in your plant. Learn why world class companies are adopting lubrication strategy, their benefits and what it can do to your plant. One of the problems most industries are facing is that we always end up being reactive despite our best efforts on Preventive Maintenance, frequent unexpected failures and breakdowns will always results to high cost of maintenance due to a lack of an effective maintenance strategy. It is with our best intention to share with you this course and resources which can be adopted in your company. It is the intention of this course to share the information and experience on Contamination Control and its benefits to plant production and maintenance people.

Text Box: Not all equipment are created equal even if they are of the same equipment type. Much of the maintenance requirements have much more to do on how the equipment will be operated or the operating conditions of the equipment. This course covers the principles of RCM which is a process used to determine the maintenance requirements of any physical asset in its present operating context. It entails us by asking 7 questions about the asset that is being maintained. This course provides an indebt details and understanding that the aim of maintenance is not about eliminating failures but rather understanding that each failure have their unique form of consequences and that the degreed of maintenance requirements should be based upon the consequences of failure itself. Likewise, this course allows us to understand that the best maintenance strategy should not just be confined to the limits of traditional Preventive Maintenance only. Maintenance must understand that the behavior of failure occurs in 3 patterns which is Infant Mortality failures, random failures and age-related or wear out failures and that only around 20% of equipment failures conform to an age-related pattern.

Text Box: This course covers the principles of TPM’s Planned Maintenance Four Phases to Zero Unplanned Breakdown Strategy. Phase One deals with Stabilizing MTBF, main activity involved here is restoration by establishing our equipment Basic Equipment Condition. Phase Two is all about Addressing Equipment Weaknesses in Design & 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. Phase Four of Planned Maintenance is all about determining the parts that will undergo Predictive maintenance through a system known as Condition-Based Maintenance and the application and use of diagnostic tools to monitor equipment parts condition.

Text Box: This course shows the importance and benefit of a Condition-Based Maintenance (CBM) program. The benefits of such a program will be realized in greater equipment reliability and longevity while at the same time enhancing budgetary cost containment goals. Operations and Maintenance will make a sound maintenance & operating decisions based on actual equipment performance rather than relying on the old standard of Time-Based maintenance intervals or even less desirable circumstance or waiting for the equipment to fail in service. According to maintenance specialists, at least $250 billion of parts are wasted. Ineffective maintenance strategy is responsible for equipment failures, disrupted production schedules, delays in deliveries & poor production quality.

Text Box: In today's manufacturing industries, more and more companies are seeking ways to improve their plant’s performance through the application of continuous improvement tools such as TPM. Although it originated from the Japanese, TPM is not culture bound but rather its principles can be applied to any culture as long as people accept TPM as a way of life. TPM improves the manufacturing process through utilization of employee involvement, empowerment and closed-loop measurement of results. Learn the basic principles of TPM and how it can apply to your industry . . . . .

Text Box: As maintenance professionals we know the importance of maintenance to our organization goals and objectives. The difficulty is in translating the overall company strategy to a meaningful measure of performance. The old saying that if you can't measure it, you cannot manage it " is as true for performance as for anything else. Much of what is meant by performance often appears to be immeasurable. It's OK looking at how things happened after the event & traditional measures can do this. What a manager needs is a much more dynamic, real time view of performance as it happens. People are central to this and qualities like motivation, confidence, leadership and perception are what is needed to be understood. But before we can use them we need to understand these measurements.

Text Box: OEE is the primary measure of performance in TPM. It is calculated by multiplying the availability, efficiency and quality rate of an equipment. This course allows us to understand the 7 major losses we suffer each day and its relationship with OEE. Each losses is being discussed in detail and how it can reduced or eliminated. What is important is for our people to understand what losses our equipment is suffering & how to measure it.

Text Box: Being World Class means the ability to compete anywhere in the world. World Class Maintenance Management simply means the art and science of managing maintenance resources performed by best in class industries from around the world. But in most industries, the question is often raised, is it really possible to control maintenance or the pressure over maintenance is controlling us. This course provides a discussion on how failure occurs in 3 zones and why most of our efforts on maintenance only addresses one zone which is the wear out failures. This course also covers the 12 Discipline in order to improve equipment’s reliability. These 12 Disciplines are categorized into Three, The Basics, The Strategies and Advance Discipline. Learn what these disciplines are that most World Class companies perform.

Text Box: This course is a streamlined approach on RCM or Reliability-Centred Maintenance. This is a two in one course where the basic principles of RCM are covered & how we can derive an approach on determining our maintenance requirements for our assets based from our existing procedures. OER is a strategy & method for improving the effectiveness of current maintenance. programs and strategies. It starts with the existing maintenance program used within the plant. Working in cross functional teams from the shop floor, the team identifies what type of duplication exists within their own environment and what elements of the current maintenance program are useful and what are inappropriate. Once this is completed, the team establishes the most efficient and effective method for managing the maintenance of the asset.

Text Box: This course shows the importance and benefits of introducing an Autonomous Maintenance strategy and what it will achieve if correctly applied in the workplace. Autonomous Maintenance are the activities in which each worker performs daily cleaning, lubrication, inspection and parts replacement in order to establish Basic Equipment Condition. This course tells us the importance that Autonomous Maintenance is not just the transfer of task to operators but teaching operator that their responsibility does not end from just operating the machine itself. Autonomous Maintenance is about changing the mindset of operators from I fix you operate to operators take care of our equipment.

Text Box: This course covers the four strategies of Basic Maintenance Concept w/c are Reactive, Preventive, Predictive and Proactive and when each of them is feasible to use. Reactive Maintenance : This type of maintenance strategy simply means fixing it only when it fails as the saying goes when it ain’t broke don’t fix it when it fails then we come and fix it. In Preventive Maintenance, maintenance is performed on a fixed or scheduled Time-Based interval. Parts in which the rate of wear is directly related with age are subject to this type of tasks. Predictive Maintenance is performed not based on time but rather on the condition of equipment with the aide of diagnostic monitoring tools to determine the potential failures and lastly in Proactive Maintenance we are interested to Determine the Root Cause of the failure and correct it permanently to prevent recurring failures from recurring again in our equipments.

Text Box: PRO - Understanding Proactive Maintenance – Achieving A Culture of Reliability ( 1 day )

Text Box: It is a common practice due to lack of time and information that equipment and system failures are often investigated at a superficial level. As a result both operators and maintenance keep running unreliable plant, which cause repeated losses & become experts at fixing rather than eliminating the failure. This seminar you will learn to apply several practical systematic method for analyzing performance problems to uncover the root cause that will eventually end all recurring problem making us proactive. Most maintenance are contended with fixing and repairing failures, in fact we accept them as a normal routine work, stock up piles of spare parts in our inventory to make sure that they are available whenever a failure occurs. Fixing failures is a thing of the past for companies who would like to improve their equipment reliability, their secret, they analyze their failures and determine the Root Cause of the problem so that appropriate solutions can be adopted. Trouble shooting is no longer an effective strategy. In today’s competitive word of, the “Analysts” find real solutions, that’s why the need to understand Root Cause Failure Analysis is a must . . . . .

Text Box: This course explains the facts why typically an industry remain reactive in nature. Being reactive simply means that addressing a failure when it happens, failure will come first and maintenance react on it. Even with the best structure on Preventive Maintenance and top of the line software's at hand, PM can't capture all the failures. Failures are inevitable and occur in three patterns, Infant Mortality, Random Failures and Wear or age-related failures, Understanding this failure patterns will definitely allow us to have a better perspective about how to derive a holistic structure that will capture majority of these equipment failures.

Text Box: Every industry have some form of Preventive Maintenance approach they are using. But despite these noble efforts in their equipment, a lot of problems and firefighting approach exists. This course will allow us to learn what Preventive Maintenance can do and what it cannot do. This course also provides useful information and a detailed step by step approach on how to optimize and maximize the use of your Preventive Maintenance so that it can well serve its purpose. Learn what we need to know about PM and how to deal with the problems we encounter on Preventive Maintenance

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There is no silver bullet solution or rocket science program or strategy that can transform a plant’s reliability overnight, all will start with its basic foundation and that is through “EDUCATION”. Remember that reliability is not a program with an end but a culture that never ends, it is the same as any continuous improvement philosophy . . . . . .

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RELIABILITY & MAINTENANCE CONSULTANCY FIRM

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Text Box: Gallery: New pictures for 2010 added from the gallery portion. Newsletter: May 2010 Edition finally released to our subscribers. Email me if you want to subscribe to our Newsletter. 2010 Training Schedule: If you are interested to attend in any of our public workshop and master class for 2010. Send us an email or register online. WCM Book: If you’re interested in buying the book on World Class Maintenance, The 12 Disciplines. Send me an email to reserve. WCM Book is now available. Get your copy now. In-house Training :Should your industry be interested for in-house trainings we’re now accepting regular schedules for in-house training for both local and international countries on courses offered. Contact us now. Email us l

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Text Box: Our Reliability Newsletter will be provided once a month to our valued subscribers. It provides highlights as well as issues and lessons regarding our most common link which is all about improving the reliability of equipment.

Text Box: Registration at this forum is done through administration only. Should you be interested to join send me an email and we will provide you with a user ID and password. Visit my discussion board and forum . . Click Here !!! Share what you know. Come and join our RSA Maintenance Forum. Send me an email

Text Box: Select the courses of your choice and it can be made available in CD . Click Here !

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Text Box: We are very much flattered and humbled by your feedback and testimonies. Your messages are the main reason for allowing us to stay in this business. With all humility we say thank you and rest assure that we are continuously improving. Without your support in our training there won’t be us. Read More !

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Text Box: World Class Maintenance Management - The 12 Disciplines Book is now available here. This is not only about the technical jargon on reliability and maintenance, it is a book that makes every single maintenance proud that they belong to the maintenance function. If you have been living through the day to day pressures of doing maintenance then this is your story. If you are interested in this book, send me an email. Click Here !

Text Box: World Class Maintenance Book (Now Available)

Text Box: Greatest Performer and Humanitarian of all times (1958-2009)

Text Box: This portion is dedicated not only to the greatest performer of all times but also to the greatest humanitarian the world had ever known, Michael Jackson. We bid you goodbye and we shall never forget you. In behalf of my family and my small firm RSA Reliability we salute you. Your music and your message lives on.