About CMRP
Effective Maintenance Management and Reliability Practices (SMRP BOK – CMRP oriented)
Effective Maintenance Management is the hub of a well-functioning maintenance organization. In order for maintenance to work, many other systems need to work well. Most importantly work identification of what to do and how to do it.
This comprehensive 5-day program has been designed based on SMRP Book of Knowledge to benefit both new professionals and experienced professionals. It covers advanced best maintenance practices that a qualified professional would require to carry out his duty starting with the first steps and building up knowledge and experience to a fully functional maintenance organization.
Course Objective:
By the end of the course, participants will understand and learn:
• The 5 Pillars of SMRP BOK
• Leading their Organization and Management into Planned Maintenance effectiveness
• Understand new maintenance methodologies and their application
• Identify and plan best practices for an effective maintenance and reliability program.
• Improve the use of information and communication tools between related parties and/or departments in Maintenance and Reliability.
• Improve consistency and reliability of asset management
• Utilize leadership and personal skills to achieve maintenance and reliability excellence
• Optimize preventive and predictive maintenance strategies to maximize returns.
Course Outline
Introduction
O Definitions in Maintenance
O Evolution of Maintenance Methodologies (TPM – RCM – LEAN)
O What is SMRP
O Why CMRP
1. Pillar 1 – Business and Management
1.1. The P-F Curve: understanding Maintenance over Asset Lifecycle.
1.2. Maintenance types: Reactive / Periodical / Condition Based / Proactive
1.3. Provide Vision and measurable goals
1.4. Ratio of Replacement Asset Value (RAV) to Craft-Wage Head Count
1.5. Stocked Maintenance, Repair, and Operating (MRO) Inventory Value as a Percent of Replacement Value
1.6. Total Maintenance Cost as a Percent of Replacement Asset Value
1.7. Communicate with stakeholders – reporting and Dashboards
1.8. Maintenance coordination with EHS2. Pillar 2 – Manufacturing Process Reliability
2.1. Understanding Process and its parameters
2.2. Flow diagrams: SIPOC / VSM
2.3. What is process improvement
2.4. Understanding waste and variability – Lean Six Sigma
2.5. Total Productive Maintenance – TPM and Overall Equipment Effectiveness (OEE)
2.6. Total Effective Equipment Performance (TEEP)
2.7. Uptime, Idle Time, and Utilization Time
2.8. Change Management3. Pillar 3 – Equipment Reliability
3.1. Visual Management and 5S Methodology
3.2. Systems Covered by Criticality Analysis
3.3. Reliability expectations and measurements
3.4. Scheduled and Unscheduled Downtime
3.4.1. Mean Time Between Failures (MTBF)
3.4.2. Mean Time to Repair or Replace (MTTR)
3.4.3. Mean Time Between Maintenance (MTBM)
3.4.4. Mean Downtime (MDT)
3.4.5. Mean Time to Failure (MTTF)
3.5. Root Cause Analysis – RCA – techniques
3.5.1. 5Whys
3.5.2. FMEA
3.5.3. Ishikawa Diagram
3.5.4. FTA |
3.6. Essential Data Analysis and Visualization
3.6.1. Data, information, knowledge
3.6.2. Data Integrity
3.6.3. Essential Statistics
3.6.4. Data Charting and visualization
3.7. Cost benefit analysis
4. Pillar 4 – Organization and Leadership
4.1. inventory staff skills, determine performance gaps
4.2. Develop the organization structure (establish reporting channels, determine roles and responsibilities.
4.3. Maintenance Training Cost /hours
4.4. Maintenance Training Return on Investment (ROI)
5. Healthy work environment
5.1. Leadership role
5.2. Basic motivation theories
5.3. Avoiding the blame culture
5.4. The cycle of decision making
5.5. Understanding team development phases
6. Pillar 5 – Work Management
6.1. What is a Prioritization System?
6.2. Essential Maintenance Planning skills
6.3. Essential Maintenance Scheduling skills
6.4. Maintenance Shutdown Costs
6.5. Actual Cost to Planning Estimate
6.6. Planning Variance Index
6.7. Planned Backlog /Ready Backlog
6.8. Work Management KPIs
6.8.1. Preventive Maintenance (PM) & Predictive Maintenance (PdM) Work Orders Overdue
6.8.2. PM & PdM Yield and Compliance
6.8.3. Craft Worker to Supervisor / to Planner ratios
6.8.4. Direct to Indirect Maintenance Personnel Ratio
6.8.5. Overtime Maintenance Cost
6.8.6. Stores Management essentials
6.9. Maintenance Documentation system/structure – Effective reporting
6.10. Continuous monitoring and analysis
7. Extra topics (according to time)
Parking lot of any left-over topics from previous days
Review Quiz (can be divided on previous days according to group progress)
(SIMULATED CMRP EXAM) |
