Introduction:

The reliability of mechanical equipment is vital for seamless industrial operations. Equipment downtime and failures result in productivity loss and increased costs. This course provides a comprehensive understanding of maintenance strategies, failure analysis, and reliability optimization techniques to ensure equipment performance and durability.

Objectives:

  • Gain an in-depth understanding of reliability-centered maintenance (RCM) concepts.
  • Identify and analyze common failure modes and their root causes.
  • Apply advanced predictive and preventive maintenance techniques.
  • Optimize maintenance planning for cost-efficiency and effectiveness.

Course Outline:

Day 1: Overview of Maintenance and Reliability Concepts

  • Introduction to maintenance types and their significance.
  • Overview of reliability-centered maintenance (RCM).

Day 2: Preventive Maintenance Strategies

  • Scheduling and planning for preventive measures.
  • Real-world examples and their benefits.

Day 3: Predictive Maintenance Tools and Techniques

  • Vibration analysis, infrared thermography, and acoustic monitoring.
  • Practical application of predictive tools.

Day 4: Corrective Maintenance Planning and Execution

  • Root cause analysis of equipment failures.
  • Methods for implementing corrective actions effectively.

Day 5: Failure Mode and Effects Analysis (FMEA)

  • Workshop on identifying critical failure modes.
  • Risk prioritization exercises.

Day 6: Condition Monitoring Techniques

  • Utilizing condition-based monitoring systems.
  • Case studies on condition monitoring success stories.

Day 7: Oil Analysis and Lubrication Strategies

  • Hands-on oil sampling and analysis techniques.
  • Best practices for lubrication maintenance.

Day 8: Developing Maintenance KPIs

  • Selection of KPIs aligned with organizational goals.
  • Methods for tracking and improving maintenance performance.

Day 9: Real-World Scenario Simulations

  • Group activities simulating maintenance challenges.

Day 10: Practical Planning and Troubleshooting Workshop

  • Development of a maintenance action plan.
  • Group presentations and peer reviews.