Topic outline

  • Cost Management and Maintenance Management

    This course covers systematic techniques on cost management and maintenance management for maintenance managers, maintenance engineers, maintenance supervisors, maintenance foremen, asset managers, housing services supervisors, property managers, maintenance & engineering consultants, project managers and those who are involved in maintenance and operations (M&O) in consultant, contractor or operating companies.

    • Training Methodology & Objectives

      Training Methodology

      This Trainee-centered course includes the following training methodologies:-

      • Talking presentation Slides (PPT with audio)
      • Simulation & Animation
      • Exercises
      • Videos
      • Case Studies
      • Gamification (learning through games)
      • Quizzes, Pre-test & Post-test

      Course Objectives

      After completing the course, the employee will:-

      Apply and gain an in-depth knowledge on cost management and maintenance management Discuss maintenance and reliability, maintenance cost facts and figures and maintenance policies development over time
      Carryout predictive maintenance, maintenance and reliability best practice and corrective maintenance Apply preventive maintenance, cleaning, lubrication, adjusting, tightening, testing and calibration, scheduled replacement, short repairs, periodic inspection and rebuilding
      Identify the factors that affect the efficiency of PM and classify maintenance policies Recognize the major parameters used for detection of machine faults and employ vibration monitoring, infrared thermography monitoring and ultrasonic monitoring
      Apply proactive maintenance and determine equipment failure process and causes, the p-f curve concept, equipment failure patterns, fundamental causes of failures and faulty design Describe the defects due to inadequate material selection, processing and manufacturing defects, assembly and installation errors and improper operation
      Identify maintenance deficiencies, latent (organizational) deficiencies, the benefits of root cause failure analysis and the three levels of cause covering physical, human and latent causes List the steps for root cause failure analysis, types of interviews and the 7-step process
      Carryout preventive maintenance optimization, life cycle cost analysis and pump life cycle cost calculation Identify risk issues in maintenance budgeting, manage maintenance budget and build a long-range plan to optimize your budget
      Apply cost engineering and management, cost estimating and the project life cycle, project cost management processes, maintenance cost control and variance management Implement project management plan, total productive maintenance, overall equipment effectiveness, availability calculation, performance calculation and quality calculation
      Discuss the principles of total productive maintenance and perform workforce management, employee life cycle and succession planning Establish and maintain learning environment, apply maintenance planning and scheduling as well as discuss the responsibilities of planner and scheduler
      Calculate the benefit of planning, choose a planner, apply continuous improvement and manage change Classify and resolve problems effectively, apply the 7-step formula for problem solving and describe the PDCA cycle
      • Course Description

        This E-Learning course is designed to provide participants with a detailed and up-to-date overview of cost management and maintenance management. It covers the maintenance, reliability, maintenance cost facts, figures and maintenance policies development over time; the predictive maintenance, maintenance and reliability best practice and corrective maintenance; the preventive maintenance, cleaning, lubrication, adjusting, tightening, testing and calibration, scheduled replacement, short repairs, periodic inspection and rebuilding; and the factors that affect the efficiency of PM and classify maintenance policies
        Further, the course will also discuss the major parameters used for detection of machine faults; the vibration monitoring, infrared thermography monitoring and ultrasonic monitoring; the proactive maintenance, equipment failure process and causes; the p-f curve concept, equipment failure patterns, fundamental causes of failures and faulty design; the defects due to inadequate material selection, processing and manufacturing defects, assembly and installation errors and improper operation; the maintenance deficiencies, latent (organizational) deficiencies; the benefits of root cause failure analysis and the three levels of cause
        During this course, participants will learn the steps for root cause failure analysis, types of interviews and the 7-step process; the preventive maintenance optimization, life cycle cost analysis and pump life cycle cost calculation; the risk issues in maintenance budgeting; the cost engineering and management, cost estimating and the project life cycle, project cost management processes, maintenance cost control and variance management; the project management plan, total productive maintenance, overall equipment effectiveness, availability calculation, performance calculation and quality calculation; the principles of total productive maintenance, workforce management, employee life cycle and succession planning; establishing and maintaining learning environment; the maintenance planning and scheduling; the responsibilities of planner and scheduler; the benefit of planning; the continuous improvement and managing change; classifying and resolving problems effectively; the 7-step formula for problem solving; and the PDCA cycle
        • Module 1 - Understanding Maintenance & Reliability

          Contents:
            • What Maintenance Is?
            • Understanding Reliability
            • Video: The 5 Pillars of Maintenance and Reliability
            • Maintenance Cost Facts & Figures
            • Maintenance Cost Facts & Figures
            • Maintenance Policies Development Over Time
            • Growing Maintenance Expectations
            • Maintenance Policies
            • Predictive Maintenance (PDM)
            • Maintenance & Reliability Best Practice
            • Definition
            • Features
            • What are the Best Practices?
            • Corrective Maintenance (CM)
            • Preventive Maintenance (PM)
            • What is Preventive Maintenance (PM)?
            • Cleaning
            • Lubrication
            • Adjusting and Tightening
            • Testing and Calibration
            • Scheduled Replacement
            • Short Repairs
            • Periodic Inspection
            • Ratio of PM to CM
            • Advantages
            • Disadvantages
            • The factors that affect the efficiency of PM
            • Predictive Maintenance (PDM)
            • Major Parameters used for Detection of Machine Faults
            • Vibration Monitor
            • What is Machine Vibration?
            • Infrared Thermography Monitoring
            • What is Thermography?
            • Thermography - Introduction
            • Thermography - Uses
            • Thermography - Benefits
            • Thermography - Mechanical Defects 
            • Belt drive
            • Combustion Engines
            • Transformer low oil
            • Motor
            • Electric motor bearing
            • Valves
            • Steam System
            • Fluid/ Steam System
            • Tank Level
            • Thermography
            • Ultrasonic Monitoring
            • What is Ultrasound?
            • Applications
            • Measuring
            • Leak Detection
            • Steam Traps
            • Valve Leak Detection
            • Leak Detection
            • Bearing Lubrication
            • Bearing Faults
            • Ultrasonic - Pump Cavitation
            • Ultrasonic - Electrical Inspection
            • Ultrasonic Monitoring - Setting a Baseline
            • Ultrasonic Monitoring - Advantages
            • Ultrasonic Monitoring - Cost
            • Proactive Maintenance
            • Module Quiz
          • Module 2 - Equipment Failure Process & Causes

            Contents:
              • Introduction
              • The P-F Curve Concept
              • How Failures Appear?
              • Video: Animation Of 2015 Explosion At Exxonmobil Refinery In Torrance, CA
              • Equipment Failure Patterns
              • First Generation
              • Second Generation
              • Fundamental Causes of Failures
              • Module Quiz
            • Module 3 - Root Cause Failure Analysis " RCFA"

              Contents:
                • The Benefits
                • Root Cause Failure Analysis " RCFA"
                • Video: Root Cause Analysis (RCA) Process
                • The Three Levels of Cause
                • Do Not Attempt to Fix Blame
                • Steps for Root Cause Failure Analysis
                • The Five P’s of Root Cause Failure Analysis
                • Parts
                • Steps for Root Cause Failure Analysis
                • Parts
                • Paper
                • Position
                • People
                • Steps for Root Cause Failure Analysis
                • People – Example of questions to ask
                • Paradigms
                • Steps for Root Cause Failure Analysis
                • Module Quiz
              • Module 4 - Preventive Maintenance Optimization (PMO)

                Contents:
                  • PMO - Introduction
                  • Video: 5 Tips For A Successful Preventive Maintenance Strategy
                  • PMO - Process
                • Module 5 - Life Cycle Cost Analysis

                  Contents:
                    • Why use LCCA?
                    • Initial (Acquisition) Costs
                    • Future (Sustaining) Cost Typically 2 to 20 times acquisition costs
                    • Life Cycle Cost Analysis
                    • Video: Transparency of Your Life Cycle Cost with our Solutions
                    • LCC Analysis for Pumping System
                    • Life Cycle Cost Analysis - Case Study
                    • Pump Life Cycle Cost Calculation
                    • Module Quiz
                  • Module 6 - The Maintenance Budget

                    Contents:
                      • Identifying Risk Issues in Maintenance Budgeting
                      • Maintenance Budget Preparation & Control
                      • The Operating Budget
                      • Annual budgeting
                      • Manpower
                      • Materials
                      • Parts
                      • Consumables
                      • Tools and Technical Resources
                      • External Assistance
                      • Managing the Maintenance Budget
                      • Budget Development – Creating the Foundation
                      • Where to Start
                      • Following Business Processes
                      • Review – Collect Data and Review Results – Bad Actors
                      • Create Improvement
                      • Focus on Leading Indicators
                      • Typical Performance Measures
                      • Build a Long-range Plan to Optimize your Budget
                      • Cost Engineering & Management
                      • Cost Estimating and the Project Life Cycle
                      • Project Cost Management Processes
                      • Video: Project Cost Management Tips: Keeping Your Project Budget Under Control
                      • Maintenance Cost Control
                      • Cost Baseline
                      • Variance Management
                      • Cost Estimates
                      • Organization Process Assets
                      • Project Management Plan
                      • Project Management Plan Purpose
                      • Module Quiz
                    • Module 7 - Total Productive Maintenance (TPM)

                      Contents:
                        • Total Productive Maintenance - Introduction
                        • Total Productive Maintenance - History
                        • Video: The History and Origin of TPM
                        • Overall Equipment Effectiveness
                        • Overall Equipment Effectiveness (OEE)
                        • Total Effective Equipment Performance
                        • Total Productive Maintenance - Principles
                        • Pillar 1: Autonomous maintenance (Jishu Hozen)
                        • Pillar 2: Focused Improvement
                        • Steps for TPM Implementation
                        • A Chart for Autonomous Maintenance
                        • Training Skill Development Matrix
                        • Steps for TPM Implementation
                        • Direct Benefits of TPM
                        • Indirect benefits of TPM
                        • Difficulties Faced in TPM Implementation
                        • The Cost of Implementing TPM
                        • Module Quiz
                      • Module 8 - Workforce Management

                        Contents:
                          • Introduction
                          • Employee Life Cycle
                          • Hire
                          • Inspire
                          • Admire
                          • Retire
                          • New Hire Selection Process / Procedures
                          • Performance Review
                          • Determining Training Needs
                          • Skills Development Training
                          • Designing Organization Structure for Better Integration of M&R Functions
                          • Succession Planning
                          • Establish and Maintain Learning Environment
                          • Video: What is Workforce Management
                          • Module Quiz
                        • Module 9 - Introduction to Maintenance Planning & Scheduling (MPS)

                          Contents:
                            • MPS - Introduction
                            • What is Wrench Time?
                            • MPS - Objectives
                            • Planning/Scheduling
                            • Planning Vs. Scheduling
                            • MPS - Defined Planning
                            • The Planner Responsibilities
                            • MPS - Defined Scheduling
                            • The Scheduler Responsibilities
                            • MPS - Benefits
                            • How to Choose a Planner?
                            • Should Planning be separate from Scheduling
                            • How Many Planners?
                            • Where Planning/ Scheduling Fits into Good Maintenance Practices
                            • MPS - Process
                            • Video: How Maintenance Planning & Scheduling Works
                            • Module Quiz
                          • Module 10 - Continuous Improvement

                            Contents:
                              • Continuous Improvement
                              • Managing Change
                              • Innovation & Improvement
                              • Kaizen is not a Synonym for Improvement
                              • Comparing Kaizen and Innovation
                              • 6 Points to Consider
                              • Why is it Necessary to Measure
                              • What is Measured?
                              • Breakdowns
                              • What is Breakdown?
                              • Breakdown Classification
                              • (MTBF) Mean Time Between Failures
                              • (MTTR) Mean Time to Repair
                              • Overall Equipment Effectiveness O.E.E
                              • Problem Classification
                              • How do you Resolve Problems?
                              • Problem Classification
                              • 7 Step Formula for Problem Solving
                              • Video: Continuous Improvement
                              • Module Quiz
                            • Module 11 - Case Studies

                              Contents:
                                • Case Study 1
                                • PMO- Case Study
                                • 2 Case Study
                                • Life Cycle Cost Analysis - Case Study
                                • Case - 3
                                • Case - 4
                                • Case —5— Self Test — Why- Why
                                • Case - 6
                                • Case - 7
                                • Case - 8
                                • Case 9— Motor Burning Case — Self Exercise
                                • Case 9-Motor Burning Case-Fish Bone Diagram
                                • Case Study 9
                                • Case Study - 10
                              • Post-Test

                                Kindly complete the post-test to assess your knowledge about the topic after the course.