Due to the explosion of computerised maintenance management systems and all the data they store, along with the realisation of the high costs associated with maintenance within an organisation, increasing attention is being paid to evidence-based maintenance through formal quantitative techniques that can be used to improve decision-making in the context of equipment maintenance, replacement and reliability. Many maintenance professionals did not formally study these techniques in their tertiary programmes.
This five-day Programme will bring participants up-to-date and make them comfortable with applying the latest developments that can be used to optimise equipment maintenance and replacement decisions.
The objectives of the programme can be summarised as follows:
(1) To focus on the techniques of optimisation – the single most important thrust of this learning programme. Whether the decision is about work-crew sizes, or the replacement of component-parts or entire equipment units, the concept of making the very best, most optimal, decision will be the principal concern of the training programme.
(2) To equip the participating maintenance and reliability professionals with the know-how to select the most appropriate analytical tools for their maintenance decision-making.
(3) To reflect the growing focus of industrial safety and the profusion of safety-related litigation – think of transportation accidents, chemical spills, and mining disasters – the programme will show how safety objectives relate to the optimisation models, and will underline the advantages of having a well-documented and rigorously-executed programme of maintenance and replacement.
(4) To introduce the critical decision-making topics that can make a significant difference to the in-service time of equipment, to the costs related to doing maintenance too often or too seldom, and the optimisation of asset utilisation.
(5) To not only cover the classic need-to-know material in the area, but to acquaint you with leading-edge and on-the-horizon approaches that you will encounter in the near future.
(6) To further ensure that you, after completion of the programme, continue to apply the course-learning to your work-place problems, each of you will receive a CD containing 400 (approx) powerpoint slides and a copy of Professor Jardine’s internationally-adopted text, Maintenance, Replacement and Reliability: Theory and Applications.
(7) Educational versions of four software packages will be made available to you. The packages are:
OREST for the optimisation of component preventive replacement decisions
AGE/CON for the optimisation of the economic life of mobile equipment
PERDEC for the optimisation of the economic life of plant and equipment
SMS for the optimisation of critical spares stockholding
Course Outline
Basic Statistics, Risk Assessment And Economics
• Analysis of component failure data
• Probability density, reliability, and hazard functions
• Definition of failure: Weibull analysis
• Dealing with censored data – three-parameter Weibull and Kolmogorov-Smirnov test
statistic
• Weibull software: OREST, RelCode, Winsmith
• How can a piece of equipment fail?
• What is the impact?
• Where do you place your maintenance efforts?
• Aspects of discounted cash flow used in capital equipment replacement analysis
• Estimating the interest rate appropriate for discounting
• Present-value calculations
• The effects of inflation in the analysis
• Calculating the Equivalent Annual Cost (EAC)
• Selecting the best alternative to minimise life cycle cost
Optimising Maintenance And Replacement Decisions
• Reliability improvement through preventive replacement
• Exercise in analysing component failure data using the Weibull distribution
• Component replacement procedures, including Glasser’s graph
• Use of OREST for optimising preventive replacement strategies
• Forecasting spare parts requirements including capital spares
• Establishing optimal component replacement procedures – case studies
• Reliability improvement through inspection – establishing optimal frequency and depth
• Reliability improvement through asset replacement
• Economic life of capital equipment
• The “classic” economic life model
• Establishing optimal replacement strategies for capital equipment -fixed and mobile –
case studies
• Use of AGE/CON and PERDEC software for capital equipment replacement
• Role of simulation to establish maintenance resource requirements
Optimising Condition Based Maintenance Decisions
• CBM from first principles
• Data acquisition, signal processing and decision-making
• A CBM information strategy
• Using “intelligent agents” in CBM
• Refining CBM inspection intervals – “the elusive P-F Curve”
• Determining the ‘significant’ condition indicators
• Optimally interpreting condition data
• Case studies including vibration monitoring of shear pump bearings in the food process industry, oil analysis of electric motors on mobile mining equipment, use of visual inspection for traction motors ball bearings, oil analysis of transmission and engines on mobile equipment, oil analysis of aircraft engines, vibration monitoring of Warman pump bearings, oil analysis of diesel engines on board ships, vibration monitoring of pumps in the pulp and paper industry