Implementing Effective Preventive & Predictive Maintenance Programmes

The training program will incorporate instructions, guidelines and orientation to:
• Understanding engineering issues in managing an effective preventive and predictive maintenance program
• Learn to apply practically to field for augmenting maintenance performance
• Understand the importance of quality control requirements during fabrication and erection
• Understanding common types of maintenance, relative advantages and disadvantages
• Classifying and developing asset database
• Modelling costs, optimizing resource applications
• Overview of vibration analysis, phase, FFT and spectrum analysis
Course Content :
Basics and Maintenance Overview
• Introductory Test / Evaluation
• What is maintenance, types and importance for an organization?
• Basic overview, the importance of logs and technical history
• Asset life cycle management overview and strategy for various stages
• Objectives, costs and modelling
• Introduction to maintenance management systems:
• Work centre’s and scheduling
• Understanding parts, part list, equipment drawings
• Role of maintenance for the organization’s profitability
• Understanding quality requirements and the importance of inspection
• Developing Inspection Plans and procedures for equipment’s
CBM – Conditioned Based Maintenance
• Life Cycle and Normal Wear and Tear
o Overview of the role of condition monitoring
• World Class Maintenance
• Types of maintenance
• Corrective maintenance
• Preventive maintenance
• Proactive maintenance
Maintenance Management Systems
• Maintenance information system
• Manufacturer recommendations in equipment manuals
• Use of right and recommended tools
• Basics of CMMS and terminology
• Prevention of equipment failure:
• Identifying failures and preventive care
• Right operations and care for equipment
• Toolbox talks and their role in care for equipment
• Spares parts, inventory management foundations
• The root cause analysis basics through examples
Predictive Maintenance Tools
• Vibration Measurement and analysis
• Measuring Vibration
• Amplitude
• Displacement
• Velocity
• Acceleration
• Frequency
• Phase
• Vibration Analysis
• Complex Vibration
• Machinery Vibration Severity
• Velocity RMS
• High-Frequency Detection System
• Components of a Signal
• Vibration Transducers
• Overall and Spectral Vibration
• Monitoring Point Location and Transducer Mounting
• Engineering requirements for reliable performance
• Vibration analysis basics
• Phase / spectrum / FFT analysis and their importance
Preventive Care & Systems, RCM Overview
• Basics of thermal cycling and fatigue damage to assets
• Reliability centred maintenance overview (RCM)
• Thermography and application for preventive care
• Risk-based maintenance method
• Review of lessons learned and activity
Other Predictive Maintenance Techniques
• Thermography
• Temperature Measurements
• Ways of Monitoring Temperature
• Infrared Thermal Imaging
• Samples
• Sensitivities and Symptom Masking
• Fault Detection Capability
Lubricant Monitoring
• Oil and Wear Debris Analysis
• Oil Analysis (Tribology)
• Sources of Wear Debris
• Fluid Monitoring/Contamination Control
• Wear in Lubricated Systems
• Wear Debris – Transport / Supervising, Monitoring Efficiency and Analysis
• Lubricant Properties and Oil Analysis
Failure Detection and Analysis:
• Equipment failure and damage modes
• How failure occur, understanding modes of failures
• Precautions
• Total productive maintenance
• Designing a maintenance management program
• Monitoring effectiveness of maintenance systems
• Restoration work management
• Task list development and estimation
• Action plan for field assets
Modern Maintenance Management Tools
• Static assets planning upkeep programs
• Failure modes and effect analysis
• Predictive maintenance planning
• Resources for improving knowledge
• Maintenance costing
• How to prevent the accumulation of old spares?
• Cost savings in managing spares effectively
• Understanding interchangeability and optimizing spares procurement
• Case study & discussions
• Evaluation test

Methodology
The training methodology integrates lectures, interactive discussions, collaborative group exercises, and illustrative examples. Participants will acquire a blend of theoretical insights and hands-on practical experience, emphasizing the application of learned techniques. This approach ensures that attendees return to their professional environments equipped with both the competence and self-assurance to effectively implement the acquired skills in their responsibilities.

DATE:

1ST BATCH:        6th – 9th May, 2025        

2ND BATCH:       18th – 21th Nov,2025