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 Mtce, 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.

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.  The maintenance requirements of an asset will depend on these 7 basic questions :

•  What  are the functions & associated performance standards of the asset in

   its present operating context ?

•  In what ways does it fail to fulfill its functions ?

•  What causes each functional failure ?

•  What happens when each failure occurs ?

•  In what ways does each failure matters ?

•  What can be done to predict or prevent each failure ?

•  What should be done if a suitable proactive  tasks cannot be found ?

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’s Basic Equipment Condition. Phase Two is all about Addressing Equipment’s 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 & the use of diagnostic tools to monitor parts condition.

This course shows the  importance & 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.

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 . . . . .

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.

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.

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’s . . . . .

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.

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 failures.

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 very 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 . . . . . .