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5-Day Preventive and Predictive Maintenance

Five-day PPM, TPM Intensive This class covers the elements of PM and PdM in a 5-day format. All aspects of PM are considered in detail including engineering, economics, management and psychology.

The 5-day course offers a comprehensive foundation for any organization wanting to improve or set-up a PM system. Delegates to this course will leave with a deep understanding of PPM and will have the ability to look at, improve or design a PM system.

In addition to the learning mentioned in the 2-day and 3-day courses the 5-day course offers in depth discussions and exercises in all the major areas. If this course is given in a plant, time can be set aside to start the review and plan the improvement of the existing PM program.

Some of the specific things you will learn include:
  • Examples and techniques to reduce labor and material waste in PM activity
  • How to look at a task to see if it impacts reliability
  • How to gain productivity through a small change in thinking
  • How to manage PM and CM activity
  • Rating existing task lists
  • Developing task lists
  • How can you insure PMs are done as designed
  • What is the economics of Planned Component Replacement and how is it used?
  • Review examples and reports from predictive maintenance?
  • Using advanced techniques such as statistical analysis and the PF curve to optimize PM.

Course Agenda Day 1:

  • Groundwork

    • The goal of Maintenance
    • PM, PdM Defined for this course
    • PM Report Card
    • 10 Questions
    • How much is enough?

  • PM Basics

    • Task lists
    • Common PM tasks
    • Review common task lists
    • Other aspects of the PM system or Program
    • A special kind of failure: Hidden Failures
    • How things fail and the kind of PM needed for each failure style

  • Introduction to Total Productive Maintenance TPM

    • TLC key to TPM

  • World Class Maintenance

Course Agenda Day 2:

  • The complete story of TPM

    • Installation of TPM
    • Attention to the 6 loses
    • Seven steps to autonomous maintenance
    • Meeting minutes
    • Measuring equipment effectiveness
    • Case Study in measuring equipment effectiveness
    • Exercise in choosing TPM tasks

  • PM Details for effectiveness

    • Different types of task lists
    • Where to get the original Task List
    • PM frequency
    • PM clocks in use

  • Advanced Concepts- PM at the next level

    • P-F Curve
    • Statistical Analysis
    • PCR

  • Predictive Maintenance

    • Questions before you start
    • Chemical and particle Analysis Predictive tasks
    • Vibration
    • Temperature
    • Visual techniques

Course Agenda Day 3:

(Calculator today)
  • Full Cost of breakdown

  • P/PM Economics

    • Past Sins
    • Costs of PM system
    • Case Study: Alternatives with Cost justifications

  • Selling PPM to management: Battle for a share of the mind

    • Selling PM to management
    • What to say when selling PM to management (identify priorities)

  • CMMS approaches to PM and PdM

    • Thoughts on installing a PM program
    • Reporting deterioration
    • Tying CM to the PM ticket
    • Shop floor automation

Course Agenda Day 4:

  • Review task lists brought in by class

  • Personnel issues

    • Staffing the PM Effort
    • What kind of personality to look for in a PM inspector
    • How to insure that PMs are done as designed

  • Get it going right

    • The big list
    • Look out; problems ahead

  • Short Repairs and high productivity

    • Justifying short repairs

  • Management of PM activity

    • Planning and Scheduling PM activity
    • Access to Equipment
    • Interruptive maintenance and non-interruptive maintenance
    • Metrics
    • Outsourcing PM

  • For TPM to work you'd better be great at Training

  • Certified operator/mechanic

Course Agenda Day 5:

  • Reliability Enhancement Programs

    • RCM
    • PMO

  • Task list development

  • Task list analysis

    • Complete analysis of task lists (line by line)

  • Action Plan

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