Advanced Maintenance Management & Reliability Improvement

Take Aways/ Outcomes

  • Learn how to identify the most effective and efficient maintenance tasks for your equipment in its operating context
  • What needs to be done to manage these tasks efficiently
  • Why reliability is not just about maintenance
  • How to identify cost-effective one off changes – including design, training and procedures – to improve equipment performance
  • How to realise results by ensuring all improvement opportunities are fully implemented


  1. Background and Introduction:
    1. the evolution of maintenance – the first, second, third and 4th generations of maintenance management
    2. traditional sources of PM programmes
    3. some reliability principles including MTBF, failure rate and ‘life’
    4. principles of Life Cycle Cost
    5. the history and development of RCM
    6. RCM standards including SAE standards JA1011 and JA1012
    7. principles behind the RCM process
    8. overview of the RCM process
  2. The Operating Context
    1. what an operating context statement should include
    2. why the operating context can affect the way we maintain identical items of equipment
  3. Functions and performance standards
    1. Primary Functions
    2. Secondary functions
    3. Protective Devices
  4. The Failed State – Functional Failures
  5. Failure modes
    1. root causes of failure
    2. at what level of detail should failure modes be described?
    3. different types of failure modes
      1. human error including training and procedural shortcomings in operations and in maintenance
      2. deterioration
      3. design/ installation errors
      4. failures caused by increasing demand or increased operations requirements
    4. criticality at the failure mode level – how is it carried out and why is it carried out
  6. Failure Effects
    1. what happens when the failure occurs – what information should be recorded and why it should be recorded
  7. The Evaluation of Failure Consequences
    1. different categories of failure consequence
      1. Safety/ Environment Consequences
      2. Hidden Failures
      3. Economic Consequences
    2. The management of risk
    3. How to determine if a maintenance task is worth doing
      1. Economic Consequences
      2. Safety/ Environmental Consequences
    4. How to build a business case for investment in a new maintenance technology or a physical redesign
  8. Proactive Maintenance Tasks
    1. How to determine if a maintenance task is technically feasible
    2. Preventive Maintenance. What is it, and what are the criteria for it to be technically feasible
    3. Condition-Based Maintenance. What is it, and what are the criteria for it to be technically feasible
      1. Performance Monitoring. How measures of equipment performance using built-in gauges and installed equipment can be used as the basis of a condition-based task
      2. Product Quality Monitoring – Monitoring the quality of a product to determine the condition of machines making that product
      3. Overview of Condition Monitoring Techniques – The use of specialised equipment to monitor the condition of other equipment
        1. Dynamic Effects Monitoring including vibration monitoring
        2. Particle effects monitoring including oil analysis
        3. Chemical effects monitoring
        4. Temperature effects monitoring including Thermography
        5. Physical effects monitoring
        6. Electrical effects monitoring
    4. Data analysis in support of RCM.
      1. Introduction to Weibull Analysis
      2. Further exploration of randomness
      3. The representation of failure data
    5. Default Actions (what if we cannot carry out a proactive maintenance task)
      1. Redesign including physical redesign and other one-off changes such as training and improved operating and maintenance procedures
      2. Redundancy and failure containment
      3. Failure Finding (the testing of protective devices)
        1. Requirements for technical feasibility of failure finding
        2. How to determine if a failure finding task is worth doing
        3. Different approaches for determining failure finding task intervals
    6. Spares decisions – how to use RCM to determine spares requirements – including consumables and insurance spares
  9. Implementing and applying RCM
    1. Facilitation and the requirements to be a successful RCM facilitator
    2. Examples of successful application of RCM
    3. Selecting assets for RCM analysis (including criticality assessment)
    4. Implementation of RCM findings
    5. KPIs – measuring maintenance and reliability performance
    6. Analysis of assets that are not subject to full RCM analysis. This includes the Maintenance Task Review Process
    7. Using RCM to drive Continuous Improvement and cultural change
    8. Dynamic aspects of RCM – what needs to happen to ensure your RCM analyses are updated as new information becomes available and people, assets and processes change
  10. Maintenance Planning and Scheduling
    1. Introduction – What is Planning & Scheduling?
    2. Sources and control of Maintenance Tasks
    3. The Basic Maintenance Planning approach
    4. Logistics –Planning materials, Equipment & Services
    5. Planning detailed job methods
    6. Planning & Scheduling KPIs
    7. The Role of the Maintenance Planner
    8. Creating the Basic Maintenance Schedule
    9. More Complex Scheduling Combinations
    10. Negotiating availability with operations/production
    11. Coping with Malfunction, Breakdown and unanticipated events
    12. How to successfully manage the outcomes of predictive maintenance activities
    13. Planning and scheduling case study

Delivery method

Learning points are reinforced by examples. Discussion and engagement are strongly encouraged. Exercises are used at several stages to ensure main points have been assimilated.

A standard case study typical of many industries (a distillate recovery system) is included so delegates will have the opportunity to apply what they have learnt throughout the course.