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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 the utilization of employee involvement, empowerment and closed-loop measurement of results.  Learn the basic principles of TPM and how it can be apply to your industry.  It took me a lot of errors and mistakes to understand what TPM is all about.  Let me share with you my actual experiences in this training on TPM.

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 is 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 and 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 what these measurements are all about.

 

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 seven 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 and how to measure it.  Learn if OEE a perfect measurement for your equipment.  TPM experts say that ones OEE reaches 85%, the equipment is already in a stage of World Class.  Learn the truth about OEE and what it is all about.

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 on 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 Disciplines in order to improve equipment reliability. These 12 Disciplines are categorized into three, the Basics, Strategies and Advance Discipline. Learn what these disciplines are that most World Class companies perform.

 

OER  -  Optimizing Equipment Reliability – Gearing From Reactive To

             Proactive Maintenance, Streamlined RCM Approach (3 days)

This course is a streamlined approach on RCM or Reliability-Centered Maintenance.  This is a two in one course where the basic principles of RCM are covered and how we can derive an approach in determining our maintenance requirements for our assets based from our existing procedures. OER is a strategy and 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. Ones this is completed, the team can establish the most efficient and effective method for managing the maintenance of the asset.

  

 

 

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 operator performs daily cleaning, lubrication, inspection and parts replacement in order to establish Basic Equipment Condition. This course tells us the importance of Autonomous Maintenance.  It is not just the transfer of task and activities to operators but  teaching operators 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  their own equipment.   This is about the 7 Step journey to operator’s empowerment. 

 

 

This course covers the four strategies of Basic Maintenance Concept which are Reactive, Preventive, Predictive and Proactive and when each of them is feasible to use.  Reactive Maintenance is a type of maintenance strategy that 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 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 happening again in our equipment.

 

 

 

 

 

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 and become experts at fixing rather than eliminating the failure. This training you will learn to apply several practical systematic methods 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 world, the “Analysts” find real solutions to problems, that’s why the need to understand Root Cause Failure Analysis is a must.

Almost all industries have a storeroom to keep parts of their equipment they need from time to time but not all these industries have the knowledge or know how to manage their storeroom and spare parts.  In fact store  room and spare parts is one of the functions on where maintenance can save on cost and almost every industry have a horrible story to tell on their storeroom that they have experience.  With the absence of a sound strategy on spare parts most of us rely on vendor on  what to stock which end up as non-moving item most of the time.  Learn the strategies on how we can improve and optimize your spare parts and storeroom.  This might be the missing link in your reliability and maintenance strategy

PBMP -  Practical Best Maintenance Practices for Industries (2 days)

 

As we all know that the cost of Maintenance is generally much more than what it should be.  Many techniques are rather talked about, learnt, planned and tried out but not much practiced maybe because it requires some discipline and detailed approach.  With this in mind, I have designed this 3 days workshop  to make you aware of what all maintenance systems and techniques are available which can be easily adopted to make your maintenance lean, productive and reliable by identifying and eliminating the wasteful practices.  As the topic indicate, this will cover a wide range of maintenance practices which is a must for today's maintenance and hence will definitely reduce the cost of doing your day to day maintenance on your equipment and assets.  It is a great pleasure to invite you all and to share and understand the best practices today in maintenance . 

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There is no silver bullet solution or rocket science program and 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 other continuous improvement philosophy . . . . . . 

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This  course  covers  the  principles  of TPM Planned Maintenance Four Phases to Zero Unplanned Breakdown Strategy.  Phase One deals with Stabilizing MTBF, main activity involved here is restoration by establishing  Basic Equipment Condition. Phase Two is all about Addressing Equipment Weaknesses 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.  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.

 

 

FI  -  Understanding TPM Focused Improvement—Kobetsu Kaizen Pillar (1 day)

 

Focused Improvement activities is used to accomplish maximum efficiency of individual facilities, equipment and manufacturing processes as well entire plants by thoroughly eliminating losses and improving performance. According to Suzuki, Focused Improvement includes all activities that maximizes the overall  equipment  effectiveness of equipment processes and plants through uncompromising eliminating of improvement losses and the improvement of performance.  It is an arena of self-accomplishment for engineers and technical staff.  These people upgrade their analytical skills in problem solving in order to improve the equipment and find abnormality   which may take precautionary measures to eliminate them and improve OEE and eliminate all equipment losses.

This course covers a wealth of information on the need to implement a holistic and robust 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 due to a high cost of maintenance because of 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 basic lubrication and contamination control and its benefits to plant production and maintenance people.

 

CBM  -  Understanding Condition-Based Maintenance – Total Approach to

             Failure Prediction & Analysis (2 days)

 

This course shows the  importance and benefit of a Condition-Based Maintenance (CBM) program. The benefits of such 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 and operating decisions based on actual equipment performance rather than relying on the old standard of Time-Based maintenance interval 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 due to improper maintenance. Ineffective maintenance strategy is responsible for equipment failures, disrupted production schedules,  delays in deliveries high costs and poor production quality.

 

Not all equipment are  created  equal even if  they are of the same type of equipment. Much of the maintenance requirements have much more to do on how the equipment will be operated or based on the operating condition 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 the seven 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 a traditional Preventive Maintenance only.  Maintenance must understand that the behavior of failure occurs in three 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.

 

MMEP  -  Meaningful Measures Of Equipment Performance - Knowing MTBF

                MTTR, MTBA, MTTF, OEE and Weibull (2 days)

OEE  -  Understanding Relationship Between Equipment  Losses and

             Overall Equipment Effectiveness (1 day)

 

RCFA -  Root Cause Failure Analysis – Understanding Equipment Failures (3 days)

AM7  -  Understanding TPM Autonomous Maintenance - Operator’s  7 Step

             Journey to Empowerment (3 days)

BMC  -   Basic Maintenance Concept – Understanding  Reactive, Preventive,

               Predictive, Proactive Maintenance (1 day)

MRO  -  Understanding MRO Storeroom and Spare Parts Management (3 days)

 

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WCM  -  World Class Maintenance Management – The 12 Maintenance

              Disciplines (3 days)

 

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PM4P  -  Understanding Planned Maintenance 4 Phases To Zero Unplanned

               Breakdown (3 days)

LUB  -   Lubrication Strategy – Understanding Tribology and The Importance

              of Oil Contamination Control  (2 days)

RCM  -   Reliability-Centered Maintenance for Industries (3 days)

 

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

World Class Maintenance Management - The Twelve Disciplines and Maintenance—Roadmap to Reliability are now available here.  WCM book speaks about the 12 Disciplines on Maintenance and MRR book is about a sequel to WCM book.  These not only cover 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!

You may view and watch these previous training slideshow  videos and together with my guitar covers on selected songs here on my You Tube Channel  and hope you subscribe for a regular update. Click Here!

 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.

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 If your industry is interested to join and participate in any of our upcoming public training and workshop for this year 2018 you  may send us an email or simply fill out the registration form provided on our schedule site.  You may Click here to visit our schedule training for 2018 Schedule.

 This portion is dedicated to the greatest band of all times “The Rolling Stones, which started in 1962 and still together. What made them stick together after simply five decades (fifty years) of music I simply can’t say,  As Keith Richards said in his book “Life. if I can excite Mick then Mick can excite the world.  Last   2012 they started celebrating their fifty years of Rock and Rolling as a band. 

 

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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 In-house Training: Should your industry be interested for any of the courses we provide for in-house trainings kindly send us an email and we will provide you with a proposal.  We are now booking reservations for in-house training for both local and international countries.     Contact us.

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