Maintenance Plan Development

What is it all about?

Asset management is a strategic function of an organisation which ensures the highest level of physical asset performance. At the heart of this function are the asset care plans (ACPs) that must manage the inherent failure modes of all of the organisation’s physical assets.

The asset care plan development process is based on the optimum maintenance mix (OMM) methodology developed by Pragma with the specific objective of assisting companies in developing and improving the asset care plans for their physical assets. The process consists of developing the optimum mixture of preventive, predictive, pro-active and reactive tactics which ensure the highest overall equipment effectiveness at optimum cost. These ACPs will turn the maintenance function into your organisation’s competitive advantage in gaining world class competitiveness.

This training course is aligned with the GFMAM’s 39 Subjects with a specific focus on the subject of operations and maintenance decision-making.

Who should attend?

  • Asset and maintenance managers
  • Project engineers
  • Production and operations managers
  • Maintenance and production engineers
  • Operational asset management team
  • Maintenance and engineering planners

What makes it different?

Pragma’s MPD utilises the powerful principles of reliability maintenance in a structured and practical format. This course aims to:

  • develop the most cost-effective ACPs by applying the seven step OMM methodology
  • avoid the analysis paralysis trap with criticality analysis (apply the 80/20 principle to maximise the initial benefit and then add to the system through continuous improvement according to world class principles)
  • establish world class asset management best practices within your organisation
  • utilise root cause analysis capability within the asset management function to improve the ACPs on an on-going basis
  • develop essential knowledge management capability to ensure sustainable improvement.

Course outline and expected outcomes

Asset management introduction

An overview of asset management and an introduction to Pragma’s Asset Management Improvement Programme (AMIP) business process in support of PASS 55.

Condition-based Maintenance

Exploring Condition-based Maintenance in more detail, by looking at the 4 most commonly used technologies, as well as other technologies available for more specific condition monitoring.

Changing world of maintenance management

How asset and maintenance practices have changed over the last 60 years, and the challenges facing maintenance managers and departments going into the future.

ACP detail development

Developing the detailed ACPs in support of the selected tactic

  • What must be done?
  • Who must do the work?
  • How long will it take?
  • What spare parts are required?
  • How long will it take?
  • How much will it cost?

ACP development process

Formalising an overall risk based approach for the development and maintenance of all the asset care plans.

ACP implementation

Putting all the ACPs together in a long term work plan and evaluating the combined effect to ensure the requirements are well balanced over the year. Is it practical from an operational context and does the budget exist to perform all the tasks?

Criticality analysis

  • Developing a formal criticality model addressing all the appropriate business risk factors
  • Applying the criticality model by performing a criticality analysis on system, asset and component levels

OMM game

Put your knowledge to the test and show how well you can manage your maintenance function!

By playing the OMM game, the seven implementation steps and the importance of choosing the right tactic for each application are identified in a practical and fun way.

Functional analysis

  • Partitioning a system or asset to a usable level for analysis
  • Identifying the function and performance standard of these partitioned assets or components

Failure analysis

  • Understanding how assets or components fail
  • Performing formal failure analysis by completing a FMEA

Tactic selection

Selecting the most appropriate maintenance tactic to manage the identified failures

  • Condition-based maintenance
  • Usage-based maintenance
  • Run-to-failure
  • Design improvement