Course Methodology

The course uses a mix of interactive and hands-on techniques. Beside the brief presentations by the consultant and the participants, there will be many individual and group exercises. The course also includes a maintenance department audit checklist which the participants will individually complete during the course to evaluate the effectiveness of their respective departments.

Course Objectives

By the end of the course, participants will be able to:

• Demonstrate the latest concepts and techniques required for managing or supervising a maintenance unit
• Examine the organizational and managerial considerations for effective maintenance work
• Apply techniques to measure Overall Equipment Effectiveness (OEE)
• Distinguish and optimize the special characteristics of maintenance activities
• Debunk safety myths and identify unsafe acts and conditions
• Identify common maintenance Key Performance Indicators (KPIs) and develop the maintenance department scorecard

Target Audience

Those involved in the supervision or management of maintenance activities; also anyone interested in learning more about the critical role of maintenance in a company.

Target Competencies

• Maintenance theory and practice
• Maintenance work processes
• Influence and communication skills
• Financial evaluation
• Safety theories and principles
• Performance management

Introduction to advanced maintenance management

• Objectives of maintenance management
• Asset management
• Maintenance life cycle
• Common maintenance management problems
• Typical responsibilities of a maintenance manager
• The maintenance organization

Continuous improvement practices in maintenance

• 5S Model to improve productivity and reliability
• Defining 5S and its principles
• Relationship between maintenance and production
• Determine needs and requirements
• Applying the principles of 5S to continuous improvement

Management of maintenance

• Maintenance strategies
• Overall Equipment Effectiveness (OEE)
• OEE calculations
• Equipment failures and patterns
• Failure modes and effect analysis
• Emergency and preventive maintenance
• Common preventive maintenance tasks
• Predictive maintenance
• Computerized Maintenance Management Systems (CMMS)
• Typical CMMS modules

 Maintenance planning and control

• Maintenance work flow process
• Work requests and work orders
• Work planning and scheduling
• Backlog management
• Resource management
• Spare parts management
• Maintenance master budget
• Capital budgeting
• Maintenance initiatives
• Replacement analysis of assets
• Maintenance operating budget
• Innovation and creativity

Safety in maintenance

• Myths about safety
• Why the concern for safety
• Unsafe acts and unsafe conditions
• Safety culture elements
• Conducting safety audits

Maintenance performance management

• Measuring and evaluating maintenance performance
• Common maintenance Key Performance Indicators (KPIs) and targets
• The maintenance balanced scorecard