/  Optimizing Equipment Maintenance and Replacement Decisions Training

Optimizing Equipment Maintenance and Replacement Decisions Training

BMC Training provides a training course in Optimizing Equipment Maintenance and Replacement Decisions in Maintenance Engineering Training

Course Title
Venue
Start Date
End Date
  • London
    15 - 12 - 2019
    19 - 12 - 2019
  • Madrid
    15 - 12 - 2019
    19 - 12 - 2019
  • Munich
    15 - 12 - 2019
    19 - 12 - 2019
  • Berlin
    15 - 12 - 2019
    19 - 12 - 2019
  • New York
    15 - 12 - 2019
    19 - 12 - 2019
  • Dubai
    22 - 12 - 2019
    26 - 12 - 2019
  • Paris
    22 - 12 - 2019
    26 - 12 - 2019
  • Hong Kong
    22 - 12 - 2019
    26 - 12 - 2019
  • Istanbul
    26 - 1 - 2020
    30 - 1 - 2020
  • Bali
    26 - 1 - 2020
    30 - 1 - 2020
  • Singapore
    26 - 1 - 2020
    30 - 1 - 2020
  • Washington
    26 - 1 - 2020
    30 - 1 - 2020
  • Dubai
    19 - 1 - 2020
    23 - 1 - 2020
  • Paris
    19 - 1 - 2020
    23 - 1 - 2020
  • Hong Kong
    19 - 1 - 2020
    23 - 1 - 2020
  • Dubai
    12 - 1 - 2020
    16 - 1 - 2020
  • Paris
    12 - 1 - 2020
    16 - 1 - 2020
  • Hong Kong
    12 - 1 - 2020
    16 - 1 - 2020
  • Kuala Lumpur
    5 - 1 - 2020
    9 - 1 - 2020
  • Rome
    5 - 1 - 2020
    9 - 1 - 2020
  • Barcelona
    5 - 1 - 2020
    9 - 1 - 2020
  • Zurich
    5 - 1 - 2020
    9 - 1 - 2020
  • London
    19 - 1 - 2020
    23 - 1 - 2020
  • Madrid
    19 - 1 - 2020
    23 - 1 - 2020
  • Munich
    19 - 1 - 2020
    23 - 1 - 2020
  • Berlin
    19 - 1 - 2020
    23 - 1 - 2020
  • New York
    19 - 1 - 2020
    23 - 1 - 2020
  • London
    23 - 2 - 2020
    27 - 2 - 2020
  • Madrid
    23 - 2 - 2020
    27 - 2 - 2020
  • Munich
    23 - 2 - 2020
    27 - 2 - 2020
  • Berlin
    23 - 2 - 2020
    27 - 2 - 2020
  • New York
    23 - 2 - 2020
    27 - 2 - 2020
  • Dubai
    16 - 2 - 2020
    20 - 2 - 2020
  • Paris
    16 - 2 - 2020
    20 - 2 - 2020
  • Hong Kong
    16 - 2 - 2020
    20 - 2 - 2020
  • Istanbul
    9 - 2 - 2020
    13 - 2 - 2020
  • Bali
    9 - 2 - 2020
    13 - 2 - 2020
  • Singapore
    9 - 2 - 2020
    13 - 2 - 2020
  • Washington
    9 - 2 - 2020
    13 - 2 - 2020
  • Kuala Lumpur
    2 - 2 - 2020
    6 - 2 - 2020
  • Rome
    2 - 2 - 2020
    6 - 2 - 2020
  • Barcelona
    2 - 2 - 2020
    6 - 2 - 2020
  • Zurich
    2 - 2 - 2020
    6 - 2 - 2020
  • Istanbul
    15 - 3 - 2020
    19 - 3 - 2020
  • Bali
    15 - 3 - 2020
    19 - 3 - 2020
  • Singapore
    15 - 3 - 2020
    19 - 3 - 2020
  • Washington
    15 - 3 - 2020
    19 - 3 - 2020
  • Dubai
    8 - 3 - 2020
    12 - 3 - 2020
  • Paris
    8 - 3 - 2020
    12 - 3 - 2020
  • Hong Kong
    8 - 3 - 2020
    12 - 3 - 2020
  • Dubai
    1 - 3 - 2020
    5 - 3 - 2020
  • Paris
    1 - 3 - 2020
    5 - 3 - 2020
  • Hong Kong
    1 - 3 - 2020
    5 - 3 - 2020
  • Kuala Lumpur
    22 - 3 - 2020
    26 - 3 - 2020
  • Rome
    22 - 3 - 2020
    26 - 3 - 2020
  • Barcelona
    22 - 3 - 2020
    26 - 3 - 2020
  • Zurich
    22 - 3 - 2020
    26 - 3 - 2020
  • London
    8 - 3 - 2020
    12 - 3 - 2020
  • Madrid
    8 - 3 - 2020
    12 - 3 - 2020
  • Munich
    8 - 3 - 2020
    12 - 3 - 2020
  • Berlin
    8 - 3 - 2020
    12 - 3 - 2020
  • New York
    8 - 3 - 2020
    12 - 3 - 2020
  • London
    26 - 4 - 2020
    30 - 4 - 2020
  • Madrid
    26 - 4 - 2020
    30 - 4 - 2020
  • Munich
    26 - 4 - 2020
    30 - 4 - 2020
  • Berlin
    26 - 4 - 2020
    30 - 4 - 2020
  • New York
    26 - 4 - 2020
    30 - 4 - 2020
  • Dubai
    5 - 4 - 2020
    9 - 4 - 2020
  • Paris
    5 - 4 - 2020
    9 - 4 - 2020
  • Hong Kong
    5 - 4 - 2020
    9 - 4 - 2020
  • Istanbul
    12 - 4 - 2020
    16 - 4 - 2020
  • Bali
    12 - 4 - 2020
    16 - 4 - 2020
  • Singapore
    12 - 4 - 2020
    16 - 4 - 2020
  • Washington
    12 - 4 - 2020
    16 - 4 - 2020
  • Kuala Lumpur
    19 - 4 - 2020
    23 - 4 - 2020
  • Rome
    19 - 4 - 2020
    23 - 4 - 2020
  • Barcelona
    19 - 4 - 2020
    23 - 4 - 2020
  • Zurich
    19 - 4 - 2020
    23 - 4 - 2020
  • Istanbul
    10 - 5 - 2020
    14 - 5 - 2020
  • Bali
    10 - 5 - 2020
    14 - 5 - 2020
  • Singapore
    10 - 5 - 2020
    14 - 5 - 2020
  • Washington
    10 - 5 - 2020
    14 - 5 - 2020
  • Dubai
    3 - 5 - 2020
    7 - 5 - 2020
  • Paris
    3 - 5 - 2020
    7 - 5 - 2020
  • Hong Kong
    3 - 5 - 2020
    7 - 5 - 2020
  • Dubai
    17 - 5 - 2020
    21 - 5 - 2020
  • Paris
    17 - 5 - 2020
    21 - 5 - 2020
  • Hong Kong
    17 - 5 - 2020
    21 - 5 - 2020
  • Kuala Lumpur
    24 - 5 - 2020
    28 - 5 - 2020
  • Rome
    24 - 5 - 2020
    28 - 5 - 2020
  • Barcelona
    24 - 5 - 2020
    28 - 5 - 2020
  • Zurich
    24 - 5 - 2020
    28 - 5 - 2020
  • London
    3 - 5 - 2020
    7 - 5 - 2020
  • Madrid
    3 - 5 - 2020
    7 - 5 - 2020
  • Munich
    3 - 5 - 2020
    7 - 5 - 2020
  • Berlin
    3 - 5 - 2020
    7 - 5 - 2020
  • New York
    3 - 5 - 2020
    7 - 5 - 2020
  • London
    14 - 6 - 2020
    18 - 6 - 2020
  • Madrid
    14 - 6 - 2020
    18 - 6 - 2020
  • Munich
    14 - 6 - 2020
    18 - 6 - 2020
  • Berlin
    14 - 6 - 2020
    18 - 6 - 2020
  • New York
    14 - 6 - 2020
    18 - 6 - 2020
  • Dubai
    21 - 6 - 2020
    25 - 6 - 2020
  • Paris
    21 - 6 - 2020
    25 - 6 - 2020
  • Hong Kong
    21 - 6 - 2020
    25 - 6 - 2020
  • Istanbul
    28 - 6 - 2020
    2 - 7 - 2020
  • Bali
    28 - 6 - 2020
    2 - 7 - 2020
  • Singapore
    28 - 6 - 2020
    2 - 7 - 2020
  • Washington
    28 - 6 - 2020
    2 - 7 - 2020
  • Kuala Lumpur
    7 - 6 - 2020
    11 - 6 - 2020
  • Rome
    7 - 6 - 2020
    11 - 6 - 2020
  • Barcelona
    7 - 6 - 2020
    11 - 6 - 2020
  • Zurich
    7 - 6 - 2020
    11 - 6 - 2020
  • Istanbul
    5 - 7 - 2020
    9 - 7 - 2020
  • Bali
    5 - 7 - 2020
    9 - 7 - 2020
  • Singapore
    5 - 7 - 2020
    9 - 7 - 2020
  • Washington
    5 - 7 - 2020
    9 - 7 - 2020
  • Dubai
    12 - 7 - 2020
    16 - 7 - 2020
  • Paris
    12 - 7 - 2020
    16 - 7 - 2020
  • Hong Kong
    12 - 7 - 2020
    16 - 7 - 2020
  • Dubai
    19 - 7 - 2020
    23 - 7 - 2020
  • Paris
    19 - 7 - 2020
    23 - 7 - 2020
  • Hong Kong
    19 - 7 - 2020
    23 - 7 - 2020
  • Kuala Lumpur
    26 - 7 - 2020
    30 - 7 - 2020
  • Rome
    26 - 7 - 2020
    30 - 7 - 2020
  • Barcelona
    26 - 7 - 2020
    30 - 7 - 2020
  • Zurich
    26 - 7 - 2020
    30 - 7 - 2020
  • London
    12 - 7 - 2020
    16 - 7 - 2020
  • Madrid
    12 - 7 - 2020
    16 - 7 - 2020
  • Munich
    12 - 7 - 2020
    16 - 7 - 2020
  • Berlin
    12 - 7 - 2020
    16 - 7 - 2020
  • New York
    12 - 7 - 2020
    16 - 7 - 2020
  • London
    19 - 7 - 2020
    23 - 7 - 2020
  • Madrid
    19 - 7 - 2020
    23 - 7 - 2020
  • Munich
    19 - 7 - 2020
    23 - 7 - 2020
  • Berlin
    19 - 7 - 2020
    23 - 7 - 2020
  • New York
    19 - 7 - 2020
    23 - 7 - 2020
  • London
    2 - 8 - 2020
    6 - 8 - 2020
  • Madrid
    2 - 8 - 2020
    6 - 8 - 2020
  • Munich
    2 - 8 - 2020
    6 - 8 - 2020
  • Berlin
    2 - 8 - 2020
    6 - 8 - 2020
  • New York
    2 - 8 - 2020
    6 - 8 - 2020
  • Dubai
    9 - 8 - 2020
    13 - 8 - 2020
  • Paris
    9 - 8 - 2020
    13 - 8 - 2020
  • Hong Kong
    9 - 8 - 2020
    13 - 8 - 2020
  • Istanbul
    16 - 8 - 2020
    20 - 8 - 2020
  • Bali
    16 - 8 - 2020
    20 - 8 - 2020
  • Singapore
    16 - 8 - 2020
    20 - 8 - 2020
  • Washington
    16 - 8 - 2020
    20 - 8 - 2020
  • Kuala Lumpur
    23 - 8 - 2020
    27 - 8 - 2020
  • Rome
    23 - 8 - 2020
    27 - 8 - 2020
  • Barcelona
    23 - 8 - 2020
    27 - 8 - 2020
  • Zurich
    23 - 8 - 2020
    27 - 8 - 2020
  • Istanbul
    27 - 9 - 2020
    1 - 10 - 2020
  • Bali
    27 - 9 - 2020
    1 - 10 - 2020
  • Singapore
    27 - 9 - 2020
    1 - 10 - 2020
  • Washington
    27 - 9 - 2020
    1 - 10 - 2020
  • Dubai
    6 - 9 - 2020
    10 - 9 - 2020
  • Paris
    6 - 9 - 2020
    10 - 9 - 2020
  • Hong Kong
    6 - 9 - 2020
    10 - 9 - 2020
  • Dubai
    13 - 9 - 2020
    17 - 9 - 2020
  • Paris
    13 - 9 - 2020
    17 - 9 - 2020
  • Hong Kong
    13 - 9 - 2020
    17 - 9 - 2020
  • Kuala Lumpur
    20 - 9 - 2020
    24 - 9 - 2020
  • Rome
    20 - 9 - 2020
    24 - 9 - 2020
  • Barcelona
    20 - 9 - 2020
    24 - 9 - 2020
  • Zurich
    20 - 9 - 2020
    24 - 9 - 2020
  • London
    6 - 9 - 2020
    10 - 9 - 2020
  • Madrid
    6 - 9 - 2020
    10 - 9 - 2020
  • Munich
    6 - 9 - 2020
    10 - 9 - 2020
  • Berlin
    6 - 9 - 2020
    10 - 9 - 2020
  • New York
    6 - 9 - 2020
    10 - 9 - 2020
  • Istanbul
    4 - 10 - 2020
    8 - 10 - 2020
  • Bali
    4 - 10 - 2020
    8 - 10 - 2020
  • Singapore
    4 - 10 - 2020
    8 - 10 - 2020
  • Washington
    4 - 10 - 2020
    8 - 10 - 2020

Introduction

  • Is your equipment (fixed or mobile) failing before planned replacement?
  • Are you unable to execute maintenance tasks because spare parts are not available?
  • Have you made significant investment in CBM methods and tools but struggle to realize the benefit?
  • Do you have lots of data from oil analyses but still struggling to accurately predict your equipment breakdowns?
  • Do you know how to determine optimum asset life?
  • Are you struggling to justify the economics of asset replacement?
  • Are you having difficulties in deciding whether to rebuild or replace your equipment to minimize the life cycle costs?
  • Do you need to optimize your emergency spare requirements?

If you answer YES to any of the above questions, this course is for you.

Objectives                                          

The objectives of the program can be summarized as follows:

  • To focus on the techniques of optimization – the single most important thrust of this learning program. Whether the decision is about work-crew sizes, or the replacement of component-parts or entire equipment units, the concept of making the very best, most optimal, decision will be the principal concern of the training program.
  • The concept of making the very best, most optimal, decision will be the principal concern of the training program.
  • To equip the participating maintenance managers, planners and schedulers and engineers with the know-how to select the most appropriate analytical tools for their maintenance decision-making.
  • Reflecting the growing focus of industrial safety and the profusion of safety-related litigation – think of transportation accidents, chemical spills, and mining disasters – the program will show how safety objectives relate to the optimization models, and will underline the advantages of having a well-documented and rigorously-executed program of maintenance and replacement.
  • To introduce the critical decision-making topics that can make a significant difference to the in-service time of equipment, to the costs related to doing maintenance too often or too seldom, and the optimization of asset utilization.
  • To not only cover the classic need-to-know material in the area, but to acquaint the participants with leading-edge and on-the-horizon approaches that they will encounter in the near future.

The Contents

Day 1 - Physical Asset Management & Reliability Concepts

From Maintenance Management to Physical Asset Management

  • Challenges of physical asset management
  • The maintenance excellence pyramid
  • Total Productive Maintenance
  • Reliability Centered Maintenance
  • Optimizing Maintenance & Replacement Decisions

Reliability Improvement through Preventive Maintenance

  • Analysis of Component Failure Data
  • Probability Density Function
  • Reliability Function
  • Weibull Density
  • Infant Mortality
  • Bath-Tub Curve

Exercise in Analysing Component Failure Data Using the Weibull Distribution

  • Estimating the Weibull Parameters
  • Using Median Rank Tables

Dealing with Censored Data, the 3-Parameter Weibull, and the Kolomorgov-Smirnov Test

  • Upper-End Censoring, Multiply Censored Group Data
  • Estimating the Location Parameter in the Weibull Distribution
  • Checking the Goodness-of-Fit of the Distribution

Day 2 - Preventive Maintenance & Spare Parts Replacements

Reliability Improvement through Preventive Maintenance(continued)

  • Component Replacement Procedures including Glasser’s Graph
  • Block Replacement Policies
  • Age-Based Replacement Policy
  • Setting Policies based on Safety Constraints, Cost-Minimization and Availability-Maximization
  • Repairable systems

Case Studies in Component Preventive Replacement

  • Including boiler plant, bearings, pumps, sugar feeds, compressor valves, and centrifuges

Spare parts provisioning

  • Fast moving spares
  • Emergency (insurance) spares

Case studies in spares provisioning

  • Including line replaceable units (LRUs), cylinder heads, repairable conveyor electric motors and utility transformers

Group and individual exercises

Clinic: Hands-On Use of PC Software for Preventive Replacement Strategies

  • Participants will solve pre-set problems

Day 3 - Machine Health Monitoring & Inspection

Reliability Improvement through Inspection

Inspection Frequency and Depth for equipment in continuous operation

  • Inspection Intervals to Maximize Profit
  • Maximizing Equipment Availability
  • Inspection Intervals for Equipment Used in Emergency Situations (e.g. protective devices)
  • Case studies including oil and gas field equipment such as pressure safely valves (for protective devices)

Health-Monitoring Procedures

  • Proportional Hazards Modelling
  • Spectroscopic Oil Analysis Programs
  • Optimization of Condition-Based Maintenance Procedures
  • Role of software for CBM optimization
  • Case studies including food procession industry (vibration monitoring), pulp and paper and shipping equipment such as compressors (vibration monitoring) and diesel engines (oil analysis), turbines in an electrical generating station (pressure measurements)

Day 4 - Economics of Reliability

Reliability Improvement through Asset Replacement

Aspects of Discounted Cash Flow Used in Capital Equipment Replacement Analysis

  • Estimating the Interest Rate Appropriate for discounting
  • Present-Value Calculations
  • The effects of Inflation in the Analysis
  • Calculating the Equivalent Annual Cost (EAC)

Economic Life of Capital Equipment

  • The “Classic” Economic Life Model
  • Before-and-After Tax Calculations
  • The Repair-vs-Replace Decision
  • Life-Cycle Costing
  • Technological Improvement

Group and individual exercises

Clinic: Hands-On Use of PC Software for Capital Equipment Replacement Analysis

  • Participants will solve pre-set problems

Day 5 - Effective Management of Maintenance Resources & Information

Effective Use of Maintenance Resources

Organizational Structure, Crew Sizes, Workshop Resource Requirements

  • Balancing Maintenance Costs against Plant Reliability
  • Establishing the optimal number of machines to have in a workshop
  • Resource Requirements Using Queuing Theory and Simulation
  • Utilization of Outside Resources
  • Lease-vs.-Buy Decision

Case studies including balancing maintenance cost and reliability in an electrical generating station, establishing optimal mix of machines to have in a steel mill maintenance workshop, establishing shift patterns and maintenance crew sizes in a petrochemical plant.

 Maintenance Management Information Systems

  • Methodology for Auditing a CMMS

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