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.  Preventive Maintenance is performed on a fixed or scheduled time-based interval. Parts in which the rate of wear is directly related to age are subject to this type of task.  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 in determining the Root Cause of the failure and correcting it permanently to prevent recurring failures from happening again in our equipment.

 

 

 

 

 

This course covers the principles of TPM Planned Maintenance Four Phases to Zero Unplanned Breakdown Strategy.  Phase One deals with Stabilizing MTBF, the 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 to classify which parts will fall on the different maintenance tasks available.  Phase Four of Planned Maintenance is 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.

 

 

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 is when each operator performs daily cleaning, lubrication, inspection, and parts replacement to establish Basic Equipment Condition. This course tells us the importance of Autonomous Maintenance.  It is not just the transfer of tasks 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.

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

           Empowerment (3 days)

OEE is the primary measure of performance in TPM. It is calculated by multiplying the availability, efficiency, and quality rate of the equipment.  This course allows us to understand the seven major losses we suffer each day and its relationship with OEE. Each loss is being discussed in detail and how it can be 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 once OEE reaches 85%, it is already in a stage of World Class.  Learn the truth about OEE and what it is all about.

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

 

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

Not all equipment is created equal, even if they are of the same type of equipment. Much of the maintenance requirements have much more to do with 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 indebted details and understanding that the aim of maintenance is not about eliminating failures but rather understanding that each failure has its 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 are 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.

LUB  -   Lubrication Strategy – Understanding Tribology and The Importance of Oil

              Contamination Control  (2 days)

 

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 adopt lubrication strategy,  their benefits, and what it can do to your plant. One of the problems most industries face is that we always end up being reactive despite our best efforts on Preventive Maintenance; frequent unexpected failures and breakdowns will always result from 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.   Learn how we can reduce wastes, failures, downtime, and costs through the application of lubrication strategies in your equipment and assets.

This course is a streamlined approach to 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 on 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 inappropriate. Once this is completed, the team can establish the most efficient and effective method for managing the maintenance of the asset.

 

 

 

 

OER  -  Optimizing Equipment Reliability – Gearing From Reactive to Proactive Maintenance,

             Streamlined RCM Approach (3 days)

As for maintenance professionals, we know the importance of maintenance to our organizational goals and objectives.  The difficulty is in translating the overall company strategy into 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 need 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.

 

 

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 maintenance pressure is controlling us.  This course discusses how failure occurs in 3 zones and why most of our efforts on maintenance only address one zone, which is the wear-out failures. This course also covers the 12 Disciplines 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.

WCM  -  World Class Maintenance Management – The 12 Maintenance

              Disciplines (3 days)

 

As we all know that the cost of Maintenance is generally much more than what it should be.  Many techniques are discussed, learned, planned, and tried out but not much practiced, maybe because it requires some discipline and a 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 adapted to make your maintenance lean, productive, and reliable by identifying and eliminating 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.

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

 

BMC  -  Basic Maintenance Concept – Understanding  Reactive, Preventive,

               Predictive, Proactive Maintenance (1 day)

 

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 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. An ineffective maintenance strategy is responsible for equipment failures, disrupted production schedules,  delays in deliveries, high costs, and poor production quality.

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

 

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, storeroom and spare parts are one of the functions on where maintenance can save on cost, and almost every industry has a horrible story to tell in their storeroom that they have experience.  With the absence of a sound strategy on spare parts, most of us rely on the vendor on what to stock, which ends up as a 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.

This course covers two of the most important strategies on maintenance, which is how to conduct a Root Cause Failure Analysis and to derive the correct maintenance tasks for our equipment and assets through the use of Reliability-Centered Maintenance.  RCFA will provide the delegates with an understanding of how to probe or investigate equipment-related failures by determining the physical, human, system, and finally, the latent cause of the problem while RCM provides a detailed approach on how to derive the correct maintenance tasks for our equipment and assets with the aid of an algorithm or Decision Diagram.  RCFA will help you learn what a true and meaningful Root  Cause Failure Analysis and how deep the probe should be to finally uncover the root causes that will eventually end recurring failures and breakdowns while RCM will determine the maintenance requirements of any physical asset in its present operating context.  RCM is done by asking seven questions about our asset or system that is being maintained.

MRR Maintenance -  Roadmap to Reliability (3 days)

 

This course covers a strategy for maintenance people to achieve high reliability of their equipment and assets through the principles of Planned Maintenance Four Phases to Zero unplanned breakdown strategy.  Phase 1 deals with Stabilizing MTBF, the main activity involved here is restoration by establishing Equipment Basic Equipment Condition.  Phase 2 deals with 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 to classify which parts will fall on the different maintenance tasks available.  This is where Reliability Centered Maintenance can be used.  Phase 4, if Planned Maintenance is about Predicting Failures through a system known as Condition-Based Maintenance and Diagnostic tools to monitor the condition of parts.

AMS Advance Maintenance Strategies on RCFA and RCM (2 days)

 

MMEP  -  Meaningful Measures Of Equipment Performance - Knowing MTBF, MTTR, MTBA,

                MTTF, OEE and Weibull (2 days)

 

CBM  -  Understanding Condition-Based Maintenance – Total Approach to Failure Prediction &

              Analysis (2 days)

 

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

 

It is a common practice due to a 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 plants, which cause repeated losses and become experts at fixing rather than eliminating the failure. In 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 problems making us proactive. Most maintenance is contended with fixing and repairing failures; in fact, we accept them as normal routine work, stock up piles of spare parts in our Inventory to ensure 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. Troubleshooting is no longer an effective strategy.  In today's competitive world, the "Analysts" find real solutions to problems.

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

 

OEE  -  Understanding Relationship Between Equipment  Losses and Overall Equipment

             Effectiveness (1 day)

 

In today's manufacturing industries, more and more companies seek ways to improve their plant's performance by applying continuous improvement tools such as TPM.  Although it originated from the Japanese, TPM is not culture-bound, but its principles can be applied to any culture as long as people accept TPM as a way of life. TPM improves the manufacturing process by utilizing employee involvement, empowerment, and closed-loop measurement of results.  Learn the basic principles of TPM and how it can be applied 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.  What took me 8 years to understand will be learned by the delegates in 3 days.

PM4P - Understanding Planned Maintenance 4 Phases To Zero Unplanned Breakdown (3 days)

 

CEMMS - Cutting Edge Maintenance Management Strategies (3 days)

 

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RSA Reliability Newsletter will be provided once a month to our valued RSA Reliability Subscribers. It provides highlights and issues, solutions, and lessons regarding our most common interest, which is all about improving the reliability of our equipment. This is a paid subscription.  A one-time payment of 49.98 USD will be required, which will be billed for you to access my newsletter vault.  You can pay via Paypal by clicking this link.

All books are written are in series based on the original concept of my first book on World Class Maintenance Management, The 12 Disciplines.  Each of these books represented a specific maintenance discipline and explained as detailed as it can be.  You can purchase these books  individually or in series depending on the book that best suit your industry.  RSA Reliability and Maintenance books are available at  www.amazon.com or check out your local bookstore.  I know and understand what it is like to be in maintenance, as this is my life.  These books do not only cover the technical jargon on reliability and maintenance, but it is also 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!

Our workshops are uniquely designed to cater to the needs of industries.  They are fun yet challenging as delegates learn more about the training.  If you would like to have any of these training done in your plant for wider participation, give us an email to submit our proposal.  Check our workshops here on this link.  These workshops have been improved and tested with time to help delegates absorbed the learning’s.  Click Here!

 If your industry is interested to join and participate in any of our upcoming public training and Master Class for this calendar year 2021, 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 2021 Schedule.

 

This portion is dedicated to the greatest band of The Rolling Stones, which started in 1962 and still together. What made them stick together after simply five decades 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-six years as a band.  They are considered the longest-running band on the planet.  What makes them great is their passion; as Keith Richard said in his book "Life," if I can excite Mick, Mick can excite the world.   This is a band that never split or separate, and they will be there together for life.

We thank our previous maintenance delegates for the trust.  We are very much flattered and humbled by your feedback and testimonies.  Your messages are the main reason for allowing us to remain and inspire maintenance people in industries.  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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Below are some references and articles that you can download for free on our most common link: maintenance and reliability. These shall be updated from time to time, as new articles will be uploaded on this site.  Also, check out our Maintenance and Reliability Newsletter.  Should you be interested in our reliability and maintenance newsletter, we will be charging a one-time payment of $ 49.99. Click here to access our free articles

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Provide an understanding of what FMEA/FMECA is all about and how this methodology can help your industry improve the reliability of your equipment and assets.  Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, machine, process, system, or product.  Failure modes mean the ways, or modes, in which something might fail. Failures are any errors, breakdown, or defects, especially ones that affect the asset or equipment.  Failures are prioritized according to how serious their consequences are, how frequently they occur, and how easily they can be detected. The purpose of FMEA is to take actions to eliminate or reduce failures, starting with the highest priority ones.

FMEA - Failure Mode and Effects Analysis (1 day)

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Serving Maintenance Mankind Worldwide

These strategies must be adopted by industries for their own advantage because, in today's phase, the law of the jungle applies, and that is, survive now or be left behind.  Cutting-Edge Maintenance Management Strategies: This book, also a sequel, deals with the different cutting-edge maintenance strategies that must be adopted by industries for them to survive their competition. In industries today, the law of the jungle applies, survives, or be left behind. Learn how these strategies can link together in building a solid maintenance structure in the plant. Finally, understand and learn these cutting-edge maintenance strategies in helping build the reliability culture for industries.  Today what every industry needs is a way on how to survive their competition and remain in business.

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 Online TrainingRSA Reliability can provide your industry online training on courses that can benefit your industry.  Online training can be done with a minimum of 2 hours to a maximum of 2 days.  Send us an email, and we will provide you with our proposal.

 RSA Newsletter Vault: This is a one time paid newsletter subscription.  If you are interested in subscribing to my newsletter vault, kindly send me an email if you want to subscribe.

 2021 Training Schedule: If you are interested in attending any of our public workshops and master class for 2021.  Send us an email or register online.

 RSA Books: If you  are interested in buying any of our books on reliability and maintenance, they are available in hardcopy, paperback and Kindle format.  These books I wrote are in series and it is best if you consider starting with World Class Maintenance, The 12 Disciplines first to understand each of the disciplines on maintenance.  This is a book which is highly recommended for every single maintenance in industries.  Limited copies.

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

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