Training Program on Systematic Plant Maintenance

Course Description:

Continuous improvement of an organization must become everyone’s business. As Maintenance departments always get step motherly treatment in many organizations, necessity for Continuous improvement is often ignored here. As a result, Maintenance Management, as an important discipline, is often ignored as a recognized discipline.

Where mantra is to move faster, it becomes the order of the day to make our maintenance more effective and efficient.

Course Objectives:

Upon Completion of this course the participant will be able to:
  • To establish a better maintenance practice
  • Planners and maintenance manager aware about better planning
  • Enhance better cooperation between operation and maintenance personnel
  • Avoid unnecessary toiling
  • Have cost effective maintenance

This training Program will also help the engineers and managers to make plant & equipment maintenance more effective and efficient through increasing moral & motivation of the employees

Organizations, where Continuous Improvement is a component of the core strategy, will find that this training program will equip the participants with the skills and knowledge of monitoring some of the key management and functional processes, which will change the way they work. The program will enable participants to think, prioritize, organize, and champion “Performance Excellence and thereby ensure greater revenue and profits to their organizations.

Who should attend: Plant Managers, Maintenance Engineers and Planners; O & M Professionals.

Instrumentation, Electrical, Mechanical and Process Engineers, Project Engineers, Maintenance engineers and supervisors interested to acquire the knowledge. The course will definitely be beneficial for the all the other department people concerned with the plant operations, maintenance and safety. It could be also useful for the procurement and quality personnel.

Whereas interested and look out of Knowledge are welcome.

The program will be a value adding experience for fresher’s to understand insight on subject matter for improving knowledge and performance.
In this training program, emphasis is given on the following areas –

  • Maintenance Philosophy – a necessary evil
  • Maintenance Management scenario
  • Various maintenance concepts – Preventive, Predictive, Condition Based and Break Down Maintenance
  • Maintenance Stratégies – sélective maintenance
  • Maintenance as a Customer focus process
  • Routine/Preventive Maintenance Planning & Scheduling
  • Predictive Maintenance Planning & Scheduling
  • Break Down Maintenance and Root Cause Analysis
  • Use of FMEA and other QC tools
  • Bench Marking in maintenance
  • Maintenance Performance Indicators
  • Maintenance Training and staff motivation
  • Maintenance through motivated employee involvement
  • Work, personnel and equipment safety
  • Basic Electrical & Mechanical Maintenance, Tribology, Lubrication, Machine Protection etc.
  • Spare part management
  • Machine reconditioning, Equipment Replacement and Investment Analysis
  • Installation of a robust, safe & effective maintenance system for the organization.

This training program may also include – Quality Circle, Idea group and other similar autonomous maintenance activities like TPM.


Course Contents and Schedule of the Program: Systematic Plant Maintenance

Day1 9:30AM - 10AM Ice Breaking with rounds of introduction; Warming up; Consensus on common Agenda, Training objectives
10:00AM - 11AM • Maintenance Philosophy – a necessary evil
• Maintenance Management as a specialized discipline
11AM - 11:30 AM Tea / Coffee Break
11:30AM - 1PM Maintenance - Various Expected Functions, Organization & Staffing
1PM - 2 PM Lunch
2PM - 3:30 PM • Maintenance Training and staff motivation
• Maintenance through motivated employee involvement
3:30 PM - 4 PM Tea / Coffee Break
4 PM - 05:30PM • Maintenance as a Customer focus process
Day2 9:30AM - 10AM Recap of Previous Day's learning; Self Assessment Quiz; General Discussion
10:00AM - 11AM • Various maintenance concepts – Preventive, Predictive, Condition Based and Break Down Maintenance
• Maintenance Strategies – selective maintenance
11AM - 11:30 AM Tea / Coffee Break
11:30AM - 1PM • Routine/Preventive Maintenance Planning & Scheduling
• Predictive Maintenance Planning & Scheduling
1PM - 2 PM Lunch
2PM - 3:30 PM • Break Down Maintenance and Root Cause Analysis
• Use of FMEA and other QC tools in maintenance
3:30 PM - 4 PM Tea / Coffee Break
4 PM - 05:30PM • Maintenance Performance Indicators
• Bench Marking in maintenance
Day3 9:30AM - 10AM Recap of Previous Day's learning; Self Assessment Quiz; General Discussion
10:00AM - 11AM • Plant specific Electrical & Mechanical Maintenance/td>
11AM - 11:30 AM Tea / Coffee Break
11:30AM - 1PM • Plant & Equipment Protection Philosophy
• Maintenance Procedures based on Work, personnel and equipment safety
1PM - 2 PM Lunch
2PM - 3:30 PM • Management of Maintenance Spare
• Machine reconditioning, Equipment Replacement and Investment Analysis
3:30 PM - 4 PM Tea / Coffee Break
4 PM - 05:30PM • Quality Circle, Idea group and CFT
• Introduction to Total Productive Maintenance (TPM)
• Session Sum up and conclusion

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