Reliability Centered Maintenance Masterclass

Setting continuous improvement methodologies for achieving higher performance, integrity & reliability in plant equipments

Mandarin Oriental Hotel, Jakarta 10th - 12th October 2011

Failure is the opportunity to begin again more intelligently

Henry Ford

Improving equipment uptime whilst enhancing operational profitability

Facilitated by international consultant:

Jan Van Kruijsbergen Principal Facilitator RCA Rt, Australia & New Zealand
Some of the international clients who have worked with RCA Rt: ABB Amcor Fibre BHP Engineering Carter Holt Harvey CNOOC/Shell CSBP Wesfarmers DOW Chemical Hazelwood Power Argyle Diamonds BHP Steel Iluka Kalgoolie Consolidated Gold Kimberly Clark Onesteel Power Coal Skilled Engineering SKF Reliability Systems Tenaga National Bhd TI Automotive Tarong Energy Western Power Yallourn Energy Anglo Quest Cadbury Schweppes CC Amatil Coogee Chemicals CSL Bioplasma EDI Rail Huntsman Chemical Auspine Boyne Smelters Incitec/Pivot Kemalex Plastics Nestle Origin Energy Rio Tinto Silcar Sunwater Tiwest Tomago Worsley Alumina Woodside Petroleum

Benefits of attending include:

Building the ideal RCM framework to suit business needs for operational excellence Identifying maintenance weak spots for enhanced RCM structure planning Enduring a global approach towards RCM to reap full benefits Obtaining improved ROI with an effective RCM framework Conducting an assessment of current performance in reliability, availability and maintenance costs Making comparison to pacesetters and identification of gaps as well as benchmarking

Testimonials from similar past events:

Planning is simple. However, majority fail to perform or execute tasks due to poor planning. This event has acquired knowledge and goal setting for my company in the future. Petronas Gas Berhad, Malaysia This event has flawlessly provided an excellent venue for participants from various organisations to share best practices and enhanced networking. Hence it will be my pleasure to recommend others to get the same opportunity and experience through marcus evans. Shell Sarawak E&P, Malaysia It is sometimes difficult to theoretically understand, but with marcus evans, you discover the know-how and to get started with your programme. Al-Ittefaq Steel Product Company, Saudi Arabia We hereby confirm benefits gained from such events where a variety of industry delegates and disciplines are interacting to satisfy a vast spectrum of industry requirements. Saudi Aramco, Saudi Arabia

marcus evans training courses are structured to provide intense and practical training. Our format:
Combinations of educational presentations, productive in-session assignments and participant collaboration to provide actionable learning Detailed pre-course questionnaires to allow you to tailor the programme to address your individual concerns Hard and soft copies of presentation materials and tools

Pre-course questionnaire
To ensure that you gain maximum benefit from this event, a detailed questionnaire will be sent to you to establish exactly what your training needs are. The completed forms will be analysed by the course trainer. As a result, we ensure the course is delivered at an appropriate level and that relevant issues will be addressed. The comprehensive course material will enable you to digest the subject matter in your own time.

*Early Bird & Group Discounts Ask about our savings

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Day 1

Day 2

Monday 10th October 2011

Session One An overview of Reliability Centered Maintenance and its role in modern proactive maintenance The structured approach to the development of maintenance and reliability tasks that has evolved out of the aviation industry has transformed the way that maintenance tasks are developed. This session reviews the development of RCM and its importance for achieving continuous improvement. The keys to success are identified. Reviewing the principals behind RCM: What real RCM is all about The need for continuous improvement in todays competitive environment Historical development of RCM RCM process overview RCM benefits case study Session Two Exploring and evaluating different RCM techniques The RCM process has developed over the last twenty years with a variety of approaches which are appropriate in different scenarios. This session looks at the various approaches, comparing, contrasting and identifying when different techniques are appropriate. Comparing and contrasting the various approaches to RCM: Identifying the appropriate solution for the organisation Key success factors: Winning RCM techniques The importance of understanding failure mode in all approaches to RCM Session Three Uncovering the role of Failure Mode and Effect Analysis in RCM This session will explain FMEA providing a number of examples and clarify its role in RCM. Delegates will learn the principles of FMEA as illustrated by a number of worked examples from a variety of industries. Understanding the functionality of real RCM and its impact on plant equipment Identifying the critical factor in all approaches to RCM: Failure modes Using Failure Mode, Effect and Criticality Analysis (FMECA) to identify critical failure modes Identifying failure mechanism and mitigating the effects of failure modes Identifying the appropriate solutions for the organisation to manage risks and promote operational excellence Session Four Devising a structured, qualitative and analytical framework of failure identification programs through Failure Mode and Effect Analysis (FMEA) Delegates will learn the detailed instructions for the correct identification and recording of Equipment Functions, Functional Failures, Failure Modes and Failure Effects that are necessary for a successful FMEA analysis. Ensuring that all critical Equipment Functions are recognised Identifying the associated Functional Failures Learning which Failure Modes must be recorded and which can be ignored Knowing which aspects of Failure Effects need to recognised and recorded for effective PM task selection Case Study Applying FMEA and completing the RCM Information Worksheet This session is a hands-on exercise in FMEA: Delegates will be presented with a real-life case study to conduct a Failure Mode and Effect Analysis (FMEA) and will learn how to effectively complete the RCM Information worksheet using FMEA. Session Five Combining RCM and RCA: Utilising Root Cause Analysis (RCA) for effective identification of Failure Modes Delegates will learn about the RCA Rt processes that have a track record of success in identifying critical failure modes. Learning the importance of a practical and methodical approach to effectively identify critical failure modes Focusing: Learning how to simplify the problem solving process by focusing on the important issues Utilising process analysis to identify failure modes Examining various failure modes using effective data analysis Finding causes: Using a fishbone diagram and brainstorming to ensure no significant failure modes are overlooked Case Study Applying RCA principles to successfully identify failure modes This session is a hands-on exercise to practice RCA: Delegates will be presented with a model of a less-than-perfect, manufacturing process and apply the principles learned in session 5 to identify Failure Modes.

Tuesday 11th October 2011

Session One Building cause and effect trees: Utilising the power of RCA to deal effectively with recurring problems. Delegates will learn how to build a logically correct and consistent cause and effect tree to identify those Failure Modes that are generally considered to be the root causes of important and/or recurring costly problems. Starting with the 5-Why approach Learning the process of cause-and-effect tree building to arrive at the correct understanding of the root cause Defining the structure of the cause tree identifying the root causes or critical failure modes Dealing effectively with hidden assumptions Case Study Building a cause and effect tree to identify root causes or critical failure modes This session is a hands-on exercise in building a logically correct cause-and-effect tree: Delegates will be presented with a workplace scenario and will learn how to identify the underlying causes and failure modes by building a cause-and-effect tree. Session Two Exploring the latest developments in Condition Monitoring for better failure prevention Understanding and effective utilisation of Condition Monitoring is at the very heart of a good RCM program. Identifying CM tasks as an effective tool to prevent random failures Understanding the PF curve and the importance of the PF interval Comparing the difference in Condition Monitoring techniques such as Vibration Monitoring, Thermal Imaging, Ultrasonic Testing and Used Oil Analysis Combining monitoring instruments to enable a "multi-parameter" approach to monitoring Incorporating predictive maintenance that are performed on machine failure over routine time-based preventive maintenance Ensuring speedy data is available for condition evaluation to analyse failures for machineries and determining optimal overhaul / replacement Case Study Defining monitoring strategies for equipment by performing fault diagnosis Delegates will learn how to choose between alternative approaches and how to determine effective task frequencies for Condition Monitoring tasks. Session Three Identifying PM tasks using RCM principles to achieve significant improvements Identifying the 4 basic types of Functional Failures Identifying the 4 basic types of PM tasks Clarifying the essential role of condition monitoring in a modern maintenance program Comparing and contrasting the use of preventive maintenance and predictive maintenance Transforming the outcomes of RCM into a practical preventative maintenance program Case Study Completing the RCM Decision Worksheet This session will include hands-on activities based on case studies and real-life examples, which will provide the delegates the opportunity to gain experience in applying these RCM techniques in their workplace to create effective PM programs. Session Four Achieving continuous improvement in your maintenance program through efficient feedback Continuous Improvement is impossible without the correct documentation and analysis tools. We need reliable feedback that leads to meaningful KPIs. This session looks in more detail at which data to collect and how to report effectively. Collecting the right data and information to enable continuous improvement and optimisation of the maintenance program Presenting an overview of the documentation management process Recording and managing important data through effective selection of software Managing the issues and the evidence from acquired feedback Utilising cause trees for more effective documentation Managing the actions required during investigations and implementation of counter measures Session Five Utilising software to effectively manage RCA and RCM activities in your organisation Simple software can be used to guide and track progress during RCA investigations and RCM analyses, achieving operational efficiency and helping to manage change effectively. Storing all relevant information in a methodical way that can be readily accessed by all relevant people Managing the actions during the implementation of an RCA and the prevention of reoccurrence of problems Utilising stored information to automatically generate reports of your activities and investigations Easy reporting to management Accessible documentation of cause and effect trees for easy future reference and fine tuning

Day 3

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Contact Marketing at marcus evans Tel: +603 2723 6611 Fax: +603 2723 6622 Email: joannek@marcusevanskl.com

Wednesday 12th October 2011

Session One Addressing the risk management of hidden failures: Using RCM to control and manage risks Managing risks: Optimising techniques of failure-finding task frequencies Using a risk matrix to optimise the maintenance approach Calculating risks associated with failures of protective and critical equipments Establishing the correct task frequencies for inspection of critical equipments based on risk analysis Session Two Revisiting the business end of maintenance through Value Driven Maintenance (VDM) and the role of RCM from a management perspective Analysing Net Present Value (NPV) and the implications in the RCM methodology Appreciating and generating the value of maintenance from a management perspective Reviewing the four pillars of VDM: Asset utilisation, HSE, cost control, allocating resources Exploring the role of RCM in adding value and improving ROI Investigating the operator involvement and adoption of Total Productive Maintenance (TPM) principles as value drivers Session Three Adopting Reliability Centered Spares Management as a preventive measure against excessive equipment downtime Integrating spares management with your plant reliability strategy, predictable failures, maintenance practices and requirements Investigating spares turnover rate through specific spare parts to obtain spares prioritisation Working with your operating and maintenance team to decide sufficient stock levels Exploring critical stock levels for uninterrupted plant operations Utilising preventive and reactive maintenance stocking considerations Organising a periodic disposal plan to release obsolete and surplus stock in inventory Case Study Defining spares requirements for equipment based on failure predictions. Session Four Implementation: Putting it all together Solving common problems and resolving disputes to improve reliability initiatives Organising your workforce to achieve effective implementation Effectively establishing the role of operators in a proper RCM implementation Deploying simple processes that yield stronger results Incorporating a strong and inclusive root cause analysis method into the RCM processes Building confidence to promote the use of RCM and RCA Identifying and solving issues found in RCM and RCA through team based activities Session Five Open forum discussion of common constraints and problems encountered in the workplace Discussion of common issues in the workplace that are making it difficult to implement reliability improvements and what can be done to tackle these effectively. Past participants often report that they solve problems during this session which have frustrated them in the past Buy-in of management Lack of resources No reliable failure data Lack of appropriate skills Poor repair techniques Reactive environment No-care attitude or lack of ownership Case Study Investigating and solving real case studies and practical problems proposed by delegates drawing on the experience of all delegates and the course facilitator.

About your course facilitator:

Jan van Kruijsbergen has more than twenty-five years experience in industry and education. He worked as a scientist, engineer, manager, consultant and industrial trainer in a variety of industries and in education. Initially as a physicist in industrial research, developing non-destructive testing equipment and procedures, he then gained experience in the manufacturing industry as Quality Control engineer / Chief Inspector / Quality Assurance Manager, responsible for administration and control of QC departments and laboratories. He performed technical writing of Quality Assurance procedures and QA manuals for accreditation purposes and conducted site audits and inspections implementing QA programs as per ISO 9001. He worked in education as a senior instructor in physics and mathematics. Since 1996 worked as consultant in the areas of reliability management, maintenance improvement, work-process improvement and root cause analysis, facilitating, auditing and training managers, engineers, planners, supervisors and trades people in a variety of industries. He also designed, developed and presented related training programs.

Why you cannot miss this event

Improvement in equipment performance is on the agenda of every plant manager today. Engineers are challenged with understanding how equipments behave and continuously look for perfect maintenance strategies that could improve their bottom line, reduce maintenance cost and increase productivity. Modern maintenance personnel as opposed to the traditional ones have to decide on the most ideal techniques to handle different types of equipment failures, to fulfill all expectations of the management, to gain active support and cooperation of manpower involved all in the most cost-effective manner. An RCM framework enables maintenance personnel to respond to challenges swiftly and simply without losing sight that maintenance is about the physical aspects of assets. This provides them the ownership of maintenance schedules and policy decisions. The end result is that the right maintenance is conducted correctly at the right interval. The objective of the RCM process is not only to increase cost effectiveness, but to also improve equipment uptime and identify the level of risk at which a company is operating. This masterclass is ideal for those who are seeking for RCM methods to achieve reliability improvements to reach target performance.

Who should attend

Vice Presidents, General Managers, Directors, Heads, Managers, Technicians, Engineers, Specialists and Team Leaders of Maintenance Reliability Plant Engineering Technical management Operations and production Integrity management Inspection From the following industries: Oil and Gas Utilities Steel and aluminium Heavy industries

Petrochemicals and Chemicals Mining Cement Manufacturing

Workshop schedule
0830 0900 1030 1100 1245 1345 1500 1520 1700 Registration and coffee Workshop commences Morning refreshments and networking break Workshop re-commences Luncheon Workshop commences Afternoon refreshments Workshop re-commences Workshop concludes

In-House Training Solutions

If you have a number of delegates with similar training needs, then you may wish to consider having an In-House Training solution delivered locally on-site. Course can be tailored to specific requirements. For further details, please use the contact information given on the last page of this brochure.

marcus evans would like to thank everyone who has helped with the research and organisation of this event, particularly the trainer, who has kindly committed and supported the event.

marcus evans reserves the right to change the venue of, or speakers at the training course should circumstances require. marcus evans

Reliability Centered Maintenance Masterclass

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10th - 12th October 2011 Mandarin Oriental Hotel, Jakarta, Indonesia

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Professional Training fee @ USD2,995+ GST / VAT (if applicable) per delegate Premier Plus - Bring 3 or more delegates to this event and benefit from a 10%
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Business Opportunities
A limited amount of exhibition space is available at the conference. Sponsorship opportunities covering the lunch and documentation also exist. For further details, please use the contact information given above.

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