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In Best Practices (RCM, TPM, RCFA, LUB) Maintenance...Module 11 : Understanding TPM • How TPM...

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RSA Reliability All Rights Reserved 2018 In Best Practices (RCM, TPM, RCFA, LUB) Rev. 2: February 18, 2018 Rolly Angeles Advance Maintenance Leadership SERVING MAINTENANCE MANKIND . . . RSA 2015
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Page 1: In Best Practices (RCM, TPM, RCFA, LUB) Maintenance...Module 11 : Understanding TPM • How TPM originated from Japan • TPM basic concept • 12 developmental steps of TPM • Preparatory,

RSA Reliability All Rights Reserved 2018

In Best Practices (RCM, TPM, RCFA, LUB)

Rev. 2: February 18, 2018

Rolly Angeles

Advance Maintenance Leadership

SERVING MAINTENANCE MANKIND . . . RSA 2015

Page 2: In Best Practices (RCM, TPM, RCFA, LUB) Maintenance...Module 11 : Understanding TPM • How TPM originated from Japan • TPM basic concept • 12 developmental steps of TPM • Preparatory,

AMD Course Objective :

• Enhance essential maintenance leadership skills to effectively perform change management and cultivate a reliable excellence culture

• Understand key principles and concepts on best practices on RCM, RCFA, CBM and leverage the learning’s from them

• Develop reliable equipment and assets through the involvement of all shop floor people in a structured and detailed program.

• Ensure successful adaptation and implemen- tation of asset management improvements with absolute compliance to maintenance

Advance Maintenance Leadership In Best Practices

• Learn the best practices on maintenance and what it takes to achieve a world class maintenance management structure in your industry

• Provide a framework on developing a corporate strategy for the maintenance function

Rolly Angeles

Advance Maintenance Leadership

SERVING MAINTENANCE MANKIND . . . RSA 2015

Page 3: In Best Practices (RCM, TPM, RCFA, LUB) Maintenance...Module 11 : Understanding TPM • How TPM originated from Japan • TPM basic concept • 12 developmental steps of TPM • Preparatory,

Course Modules on Advance Maintenance Leadership:

Module 1 : What Maintenance is All About Module 6 : Maintenance Indices/KPI

Module 2 : Changing the Maintenance Culture from Reactive to Proactive

• Common belief of maintenance • Why PM cannot capture all failures • 3 fold strategy on maintenance • Is it really possible to eliminate failures

• Correct paradigm on maintenance

• World Class Maintenance Organization

• Leading and Lagging Indicators • OEE and Equipment Losses • MTBF/MTTF Explained • Reliability Explained/Weibull Analysis

Module 8 : Life Cycle Management

Module 3 : Understanding World Class Maintenance Management

• 12 areas of maintenance discipline • Basic, the strategies and advance discipline

• Concept of Life Cycle Management

Module 4: Operators Role on Maintenance • Why Autonomous Maintenance is important • Objective of Autonomous Maintenance • Role Operators will play on maintenance

• How Oil is being contaminated • Does oil really wear out • Nominal and absolute filtration • Myths About Lubrication • 13 Strategies on Lubrication

Module 9 : Lubrication Management and Oil Contamination Control

Module 5: Leadership Strategies for Reliability and Maintenance Excellence

• The need to change the maintenance culture • Applying the 12 disciplines on maintenance

• Understanding Preventive Maintenance • Objective of a PM program • PM Planning and Scheduling • When PM is feasible to perform • Survey on Top 10 PM Problems

Module 10 : Effective Preventive Maintenance Program

Module 7 : ISO 55000 Explained

Rolly Angeles

Advance Maintenance Leadership

SERVING MAINTENANCE MANKIND . . . RSA 2015

Page 4: In Best Practices (RCM, TPM, RCFA, LUB) Maintenance...Module 11 : Understanding TPM • How TPM originated from Japan • TPM basic concept • 12 developmental steps of TPM • Preparatory,

Module 11 : Understanding TPM • How TPM originated from Japan • TPM basic concept • 12 developmental steps of TPM • Preparatory, Implementation and Stabilization • Functions, goals and roles of each TPM Pillar • Mistakes to avoid on TPM • Tips in Implementing TPM • Setting TPM year end goal

• Infant, random and age related failure • Why random failures are impossible to prevent • RCM information worksheet • RCM decision worksheet • Comparing RCM and TPM strength • How to implement RCM process

Module 15 : Basic Concept of FMEA and FMECA

Module 12 : Effective Planned Maintenance Strategy for Industries

• Understanding the concept of Planned Mtce • 4 Phases of Planned Maintenance • Case Study on Planned Maintenance

• Types of FMEA/FMECA • Purpose of FMEA/FMECA • Difference between RCM and FMEA

Module 13: Condition-Based Maintenance • Concept of Predictive Maintenance • Understanding P-F Curve • Concept of Vibration, thermography and Ultrasonic Monitoring • Starting a CBM strategy in your plant

• Preparing functions, functional failures, failure modes and failure effects

Module 16 : RCM Information Worksheet

• 7 basic questions on RCM • 6 failure patterns

• Consequences of failure • Hidden and evident failures • Safety and environmental consequences • Operational and non-operational consequences

Module 17 : Understanding the Consequences of Failure

Module 14 : Understanding RCM

Course Modules on Advance Maintenance Leadership:

Rolly Angeles

Advance Maintenance Leadership

SERVING MAINTENANCE MANKIND . . . RSA 2015

Page 5: In Best Practices (RCM, TPM, RCFA, LUB) Maintenance...Module 11 : Understanding TPM • How TPM originated from Japan • TPM basic concept • 12 developmental steps of TPM • Preparatory,

Module 18 : Understanding The Different Maintenance Tasks • Run to fail, PM, On-Condition Tasks • Failure Finding and Modification

• Evidence defined, RCFA tool kit • Types of evidences, people, physical and paper evidence • Role of Principal Investigator and the Evidence Gathering Team • How RCFA interview should be conducted

Module 19 : Maintenance Tasks

• Reactive, Preventive, Predictive and Proactive • Workshop on maintenance tasks

Module 20: Applying the RCM Process

• How RCM is implemented • Understanding the RCM Decision Diagram • RCM Decision Worksheet • RCM roadmap of activities • Understanding brittle and ductile fracture

• Physical cause of failure • Why do equipment loss its usefulness

Module 24 : Why Do Mechanical Components Fail

• RCFA explained • Difference between RCA, RCFA and Failure Analysis • When to use RCFA • Simple RCA Case Study : Missing Money • Management Role on RCFA • Workshop on Sequence of Events

• Understanding physical, human and latent cause of failure

Module 22 : Physical, Human and Latent Cause of Failure

Module 21 : Root Cause Failure Analysis

Module 23 : Evidence – The Lifeblood of Root Cause Failure Analysis

Module 25 : Understanding Human Errors • Categories of human errors • RCFA Case Study

Closing Remarks

Awarding of Certificates

Course Modules on Advance Maintenance Leadership:

Rolly Angeles

Advance Maintenance Leadership

SERVING MAINTENANCE MANKIND . . . RSA 2015


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