Day-1

• General definitions
• Overview on maintenance
• Maintenance classification based on (Cost, Priorities, Policies)
• Effective Maintenance Management Process
• Understand the different between Preventive Predictive Maintenance (PM & PdM)
• Predictive Maintenance techniques
• Understand the different between Proactive & Reactive Maintenance
• Workshop to understand the different between PM & RTF policies
• Overview on Advanced Maintenance Polices (RCM, RBI,TPM)
• How to utilize RCM and RBM to minimize the failures
• Criticality Analysis
• Reliability Excellence
• Case Study to understand the meaning of maintenance planning
• Understand the different between Maintenance planning & Scheduling
• Workshop to understand how to calculate Manpower size & Maintenance Cost

and work load distribution.

Day-2

• The road to Asset Management

• Asset Management Standardization
• Asset Management Cycle
• PAS-55-1:2008 & PAS-55-2:2008
• ISO-55000 & 55001 & 55002
• Key elements of Asset Management System
• Overview on CMMS & ERP

• What Should CMMS & ERP do
• CMMS benefits
• CMMS implementation process

• How to utilize CMMS in Asset Management & Work Management & Planning
• Controlling Maintenance Work
• Understand backlog
• Backlog route cause
• Backlog monitoring

• Causes of Equipment Failures

• Understand the Failure Code Hierarchy
• Overview on Failure classes & problem & Cause & Remedy

• Applying Root Cause Analysis (RCA)

• Failure patterns and the different between RCA & RCFA
• Choosing the appropriate maintenance task
• The role of operators: Autonomous Maintenance
• Finding root causes to improve maintenance.
• Useful tools for Determining Root Cause
• Utilize the 5 whys method & Fishbone diagram to eliminate defects.
• Case studies

Day-3

• Maintenance Activities Management

• Work Scope development & Work Package Preparation

. Procedures

. Resources Estimations (Manpower & Tools & Material)

. Building a Job Plan

. Overview on Material Requisitions & Purchase Requisitions

. Overview on Safety Plan (Hazards & Precautions & JSEA & PTW)

• Time management (Scheduling)

. Estimated Time

. Critical Path Analysis

. Pert and Gantt Diagrams

. Milestons

. Possible causes of Delay

• Progress report (S-Curve)
• Work completion and reporting
• Analysis & Improvement
• Case study (Shutdown Management using MS-Project & Excel)

Day-4

• Maintenance Assessments & Benchmarking

• Process audits
• Where are we now – benchmarking & assessments?
• What to improve – goal setting
• Action plan
• Developing an improvement action plan and fitting in modern maintenance

Technologies

• Performance Management & Implementation aspects

• Manage using KPI’s
• What is the Overall equipment effectiveness (OEE)?
• What is Total effective equipment performance (TEEP)?
• Workshop to Calculate KPI’s, OEE and TEEP
• Performance management: behavior of people

• Continuous improvement
• Implementation aspects

Day-5

• Maintenance contracts & outsourcing strategy & contractor management
• Recourse optimization using Spare Parts Management

– Material Classifications

– Understand the meaning of Lead Time

– Criticality of utilization

– Law of Pareto

– Index of Rotation (LIR & NIR)

– Spare Parts tests

– Stock holding costs

– Stock ordering costs

– Economical order quantity (EOQ)

• Workshop to calculate EOQ and Reorder level

• Maintenance budget & Cost Control

. Policies, Procedures & Rules

. Program & Budget

. Budgeting Principals & objectives

. Budget advantages

. Budget types

. Type of Costs

. Responsibility Centers

. Oil agreements and chart of accounts

. Distinguish between Capex and Opex

. Case Study

. Case study from one of gulf oil company

– Finance business process

– Budget Procedure

– Budget in Spot (AFE & Fund Check)

– Chart of account

– Sample of budget request form

– Sample of maintenance normal operating preparation sheet

(Man powers & Materials & Services)

. Why do you need a budget for maintenance?

. Sources of information for the preparation of Budget Maintenance

. Aggregation of the activities in events

. Classification of Maintenance activities by types

. Definition of volumes and resources

. Maintenance contracts & outsourcing strategy & contractor management

. Third Party Contractors

. Costs for Origin

. Costs for Destination

. Updating and prediction

. Management and control of operations

. Control of budget

. Case study

. Workshop to calculate oil and fuel consumption.

• Describe the difference between a static budget and a flexible budget.
• Develop a flexible budget.
• Define the master budget and explain its major benefits to an organization.