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Optimising Equipment Maintenance and Replacement Decisions Course

By: Citadel for Technological and Engineering Dev.

Lagos State, Nigeria

13 - 15 Oct, 2020  3 days

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NGN 120,000

Venue: CITED/BOAZ Training Centre, Nigerian Institute of Surveyor (NIS) Building, 2nd floor, Left Wing, Opposite Lagos Revenue House (formerly Elephant Cement House), ASSBIFI Road, Secretariat, Alausa

Major world companies from the process and petrochemical industry have developed their maintenance practices based on the optimization of predictive maintenance management system. This approach works well for both stationary and rotating equipment and includes continuous condition monitoring and the detailed inspection of vital elements of the equipment.

The optimization of the maintenance activities includes the spare parts handling, the selection of the right size and skill of maintenance crew with consideration of potential outsourcing i.e. subcontracting. Based on the collected data on reliability of the equipment in operation, Maintenance department can complete the Fitness for Service analysis based on which the decision can be made about 3Rs: Run, Repair or Replace, for the particular component of the equipment. Final decision regarding equipment replacement, depends very much on the economic and safety aspect that must be taken into consideration.

This programme is intended to introduce the participant to the process of making decisions regarding equipment maintenance optimization including equipment replacement. Various optimization techniques will be presented, and the optimization criteria explained. The programme will include several workshops with case studies and real-world problems to be solved. This will enable all participants to actively take part in the team work and classroom discussions

At the end of this seminar, you will learn to

  • Understand the importance of Physical Asset Management
  • Identify the modes of equipment failures, and the impact on plant reliability
  • Understand the cost-effectiveness of Preventive/Predictive Maintenance program
  • Apply techniques of optimization of various maintenance activities
  • Define criteria for work-crew size, spare parts and equipment replacement
  • Make the important decision on the basis of the cost and benefit analysis
  • Incorporate safety objectives to the equipment repair or replacement optimization

Programme Content

Physical Asset Management and Failure Analysis

  • Physical Asset Management
  • Maintenance Management: Preventive / Predictive Approach
  • Nature and Modes of Equipment Failure
  • Failure Modes and Effect Analysis (FMEA)
  • Analysis of Component Failure data using the Weibull Distribution
  • Censored Data, the 3-Parameter Weibull, and the Kolomorgov-Smirnov Test

Preventive Maintenance and Spare Parts Replacements

  • Reliability and Availability Concept: MTBF and MTTR
  • Reliability Improvement through Reduction of Downtime
  • Maintenance Performance Quantification
  • Preventive Maintenance and Spare Part Handling
  • Spare Parts Provisioning: Prediction Models and Techniques
  • Management of Change: In-Kind Spare Parts

Equipment Inspection and Fitness for Service

  • Condition Monitoring and Inspection
  • Risk Based Inspection (RBI)
  • Risk Matrix: Management and Mitigation Measures
  • Reliability Improvement through Inspection
  • Inspection Scope and Frequency
  • Fitness for Service Analysis (FFS)

Economics of Maintenance, Repair and Replacement

  • Management of Maintenance Resources
  • Effective Use of CMMS
  • Maintenance Organization Analysis: Crew size
  • Equipment Repair or Replacement Decision
  • Economic Aspect of Maintenance Outsourcing: Subcontract
  • Economic Aspect of Equipment Replacement

Total Productive Maintenance and Safety

  • Capital Investment in Equipment and Maintenance: ROI
  • Total Productive Maintenance
  • Safety in Maintenance Work
  • KPI and OEE: Leading and Lagging Indicators
  • Summary and Conclusions
CITED/BOAZ Training Centre, Nigerian Institute of Surveyor (NIS) Building, 2nd floor, Left Wing, Opposite Lagos Revenue House (formerly Elephant Cement House), ASSBIFI Road, Secretariat, Alausa Oct 13 - 15 Oct, 2020
NGN 120,000.00 + 6,000.00 (VAT)
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Engr Bola Bido 08037192728