Achieving World Class Maintenance Performance Course

Course Overview:

This course provides detailed guidelines on how to improve maintenance practices and Turnaround (T/A) management for the purposes of improving plant profitability and its reliability.

The audience will be able to benchmark their practices, identify the areas for improvement and use work justification on a risk basis. Among the strategic topics are T/A strategic development, T/A scope development and control, T/A budgeting and T/A execution. 

In addition, this course cultivates Life Cycle Maintenance Management (LCMM) concepts that make it possible for the participants to formulate maintenance strategies for key assets and integrate them into budgetary plans. 

Targeted to supervisors and managers responsible for maintenance costs and reliability, the program provides them with practical tools to increase efficiency and reduce costs.

Course Objectives:

• Understand how their plant’s maintenance practices compare with industry leaders. In addition, they will be able to identify key improvement areas and understand the steps that are required to achieve the desired savings.
• Understand the practices used by industry leaders to achieve successful T/As. They will learn the seven phases of T/A management and the actions necessary in each phase.
• Be able to conduct work request justification reviews, which are based on the business principle of return on maintenance investment. They will have an understanding of how to develop risk scenarios reflecting realistic consequences and probabilities that can be used to establish the needed scope and timing of maintenance work.
• Be able to understand the principles of Life Cycle Maintenance Management (LCMM). They will have an understanding of how to develop LCMM plans for their key equipment and the application of this information to the development of maintenance budgets

Who Should Attend?

Supervisors and Managers who are assigned the following responsibilities:

• Maintenance cost, equipment and unit reliability. Attendees should have an understanding of their plant’s current performance, maintenance practices, and opportunities for improvement.
• T/A cost and unit performance. Attendees should have an understanding of their current T/A practices.

Course Outlines:

This course is divided into four main sections:
Maintenance Practices That Improve Plant Profits

This section introduces the concepts of benchmarking maintenance performance against industry leaders. It focuses on changing maintenance philosophy and outlines top performer practices. A stepwise approach to improving maintenance performance is presented. The following topics are covered:

• Strategy for maintenance excellence
• Symptoms of poor performance
• Competitive performance
• Changing maintenance philosophy
• Top performer practices
• Achieving progress

Turnaround (T/A) Management

This section introduces the concepts associated with the successful planning and execution of major T/As. It presents milestones identifying the actions needed and their appropriate timing. The following topics are covered:

• Strategic planning
• Scope control
• Budget development and control
• Detailed planning
• Contracting
• Execution
• Close out assessment

Work Request Justification

This section introduces the concept of risk based work justification. It presents the methodology for justifying the need, scope, and timing of maintenance work. The following topics are covered:

• Organizational roles
• “Required vs. discretionary”
• Risk based decision making
• Priority setting
• Justifying work scope
• Savings/cost analysis
• Time value of money
  
  

Life Cycle Maintenance Management

This section introduces the concept behind Life Cycle Maintenance Management (LCMM). It presents a stepwise approach to develop LCMM Plans based on top performer practices. The following topics are covered:

• Define areas of vulnerability
• Identify critical components
• Timing and consequence assessment
• Assess timing and scope of maintenance intervention
• LCMM for spared equipment
• Managing LCMM data