Program Elements
1. Introduction to Maintenance Management
- Concepts and objectives of maintenance management.
- The role of maintenance in ensuring production continuity.
- Maintenance types and strategies.
- Relationship between maintenance, production, quality, and safety.
2. Maintenance Management System (MMS)
- Concept of the Maintenance Management System (MMS).
- System components and functions.
- Maintenance workflow from maintenance request to work order closure.
- Maintenance organization structure.
- Roles, responsibilities, and authorities.
3. Plant Asset and Equipment Management
- Asset Management.
- Equipment classification and coding.
- Establishing equipment and technical-location structures.
- Identification of critical equipment.
- Equipment history and maintenance records.
4. Maintenance Planning and Scheduling
- Developing maintenance plans.
- Work Planning & Scheduling.
- Determining manpower, resources, and spare parts requirements.
- Estimating labor hours and maintenance costs.
- Preparing daily, weekly, and shutdown maintenance plans.
5. Work Order Management
- Creating maintenance requests.
- Converting maintenance requests into work orders.
- Work order priority setting.
- Planning and executing maintenance work orders.
- Closing work orders and documenting results.
- Analyzing delays and maintenance backlog.
6. Preventive and Predictive Maintenance
- Preventive Maintenance (PM).
- Predictive Maintenance (PdM).
- Condition-Based Maintenance (CBM).
- Developing periodic inspection programs.
- Vibration, oil, temperature, and other condition-monitoring techniques.
7. Failure and Reliability Management
- Failure Analysis.
- Root Cause Analysis (RCA).
- Failure Mode and Effects Analysis (FMEA).
- Mean Time Between Failures (MTBF).
- Mean Time to Repair (MTTR).
- Equipment Availability and Reliability.
- Analysis of recurring failures.
8. Spare Parts and Inventory Management
- Spare Parts Management.
- Identification of critical spare parts.
- Minimum/Maximum Stock Levels.
- Reorder point management.
- Linking spare parts inventory to maintenance work orders.
- Reducing inventory costs while ensuring spare parts availability.
9. Maintenance Workforce Management
- Maintenance manpower planning.
- Allocation of technicians and engineers.
- Identification of required skills and competencies.
- Measuring maintenance workforce productivity.
- Contractor and outsourcing management.
10. Maintenance Cost and Budget Management
- Maintenance Cost Management.
- Maintenance budget preparation.
- Labor, spare parts, and contractor costs.
- Life Cycle Cost analysis.
- Evaluating maintenance costs against operational benefits.
11. Maintenance Performance Indicators (KPIs)
- Equipment Availability.
- Mean Time Between Failures (MTBF).
- Mean Time to Repair (MTTR).
- Maintenance Cost per Ton.
- Preventive Maintenance Compliance.
- Schedule Compliance.
- Planned vs. Unplanned Maintenance.
- Maintenance Backlog.
- Recurring Failure Rate.
12. Digitalization and MMS/CMMS Applications
- CMMS concepts and their relationship with MMS.
- Electronic maintenance data management.
- Maintenance dashboards and reporting.
- Mobile Maintenance applications.
- Integration with ERP systems.
- Using maintenance data to support decision-making.
13. Data-Driven Maintenance and Artificial Intelligence
- Maintenance failure data analysis.
- Predictive Analytics.
- Detection of abnormal equipment patterns.
- Failure prediction.
- Artificial Intelligence applications in industrial maintenance.
14. Maintenance Management in Steel Plants
- Specific maintenance requirements of steel plant equipment.
- Direct Reduction and Melting Furnaces.
- Rolling Mills.
- Rotating equipment.
- Motors and Gearboxes.
- Pumps and Compressors.
- Hydraulic and Automation systems.
- Maintenance management during major shutdowns and turnarounds.