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Managing Factory Maintenance

Based on popular text

Industries : This program is for all types of Factories, process industries, refineries, batch plants.

 

who : Attendees include maintenance managers, supervisors, leads, CMMS managers, planners, engineers, non-maintenance people accountable for maintenance, and people in training for these positions. There is also an advantage to having representatives from operations and stockroom for their perspective and input.

What : This 2-day class includes a spiral workbook and the text Managing Factory Maintenance Second Edition by Joel Levitt. We can schedule a tour of the production facility for insight into maintenance issues

what you will Learn :

  • Sure-fire ways to justify your maintenance expenditures
  • To integrate maintenance management into your overall strategy to increase competitiveness
  • Techniques for calculating the real cost of breakdowns
  • How to position your maintenance department to respond quickly to user demands
  • Specific methods to reduce downtime
  • How to cut costs in the storeroom
  • What questions to ask to improve customer service
  • To improve the MTTR (Mean Time to Repair) through planning
  • To calculate the real cost from a change to PM and proactive Maintenance
  • How to get operators involved and interested in maintenance issues
  • How to cut expenses buying parts
  • To evaluate existing or prospective CMMS
  • What RCM is and how it applies to maintenance management

Joel receiving an award from the CEO of SABIC for his keynote address at their Environmental, Safety and Health awards day in Jubail, KSA

Course Agenda for 2-day Managing Factory Maintenance course

In the following agenda:

RED – are interactive exercises of various types

Day 1 :

  1. Maintenance Fitness questionnaire
    • Initiation and authorization
    • Training, hiring, and development
    • PM, predictive and condition-based *
    • Planning, Scheduling
    • Guaranteed Maintainability
    • Purchasing, parts, and stores*
    • CMMS
    • Budgeting maintenance needs
  2. Spare Parts
    • Parts management
    • Parts types
    • Insurance policy parts
    • Stocking policy
    • Consignment stores
    • Re-engineering.
  3. Quick plant or process shutdown primer
    1. KPIs
    2. Phases
    3. Sources of work
    4. Validation
    5. Planned Job package
    6. Risk
    7. Resources
    8. Execution
    9. Shift schedules
    10. Shut it down
    11. Track
    12. Meeting Agenda
    13. Start-up
    14. Accurate accounting
    15. Completion
  4. PM
    1. BOK (Body of knowledge) for Factories
    2. PMO basics
    3. TPM (Total Productive Maintenance)
      • Introduction to the use and implementation
      • Tips for valid task selection, task design, and management

Day 2 :

5. CMMS Computerized Maintenance Management Systems

    1. Sample curriculum for a work order training class
    2. WO fill out Classes

6. Lean maintenance –do the right thing and save money          

  • Where to look
  • Create lists
  • Good lean project
  • Proposal

7. A case study in Job Planning

    1. Review of Planning-Coordination-Scheduling-Execution
    2. 13 essentials of job planning
    3. Adopt our planning model to save time and money on the shop floor

8. Safety in Maintenance

    1. Performing a JSA

9. Ideas for action when you get back

Training options :

We are flexible about your specific needs for outcomes from the course.

Option 1
Option 1

The most basic way is to present a standard course after a brief email conversation about goals and objectives. The courses are tried and tested and have been used to good effect worldwide in many maintenance situations.

Option 2
Option 2

The second and most common option involves a one-day site visit before the class. This visit allows me to add examples from your facility, adjust the verbal presentation to suit your needs, meet some key players, and see some of the unique problems you face.

Option 3
Option 3

involves a more extensive site visit (to be defined) a few weeks before the class. This extra time allows me to customize and add examples from your facility and adjust the verbal presentation to suit your needs. It is always good to meet some of the key players and see for myself some of the unique problems you face.

Option 4
Option 4

The third option is to conduct a maintenance audit survey that looks at all the aspects of maintenance, evaluates areas where improvements are possible, and slanting the training to the competencies needed to implement the upgrades uncovered in the survey.

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