Introduction

In light of rapid technological advancements and the increasing reliance on digital systems across various sectors, the development of Computerized Maintenance Management Systems (CMMS) has become essential to ensure efficiency and effectiveness in maintenance operations. This training program aims to equip participants with the essential knowledge and skills for planning and monitoring maintenance tasks using the latest technologies and software, contributing to improved performance, reduced operational costs, and enhanced equipment reliability.

The program will cover the latest strategies and techniques used in maintenance management, including modern maintenance systems, spare parts management, maintenance planning and scheduling, fault analysis, and the use of computers in managing preventive and predictive maintenance. Additionally, it will address maintenance contracts and types, best practices for evaluating tenders, and securing spare parts through various contracts.

Through a mix of interactive lectures, case studies, and hands-on workshops, participants will gain a deep understanding of how to use Computerized Maintenance Management Systems (CMMS) to improve maintenance performance within organizations. By the end of the program, participants will be able to apply these concepts in real-world scenarios, enhancing maintenance efficiency and achieving strategic goals for their institutions.

Objectives

• Learn the fundamentals of maintenance management systems.
• Understand different types and strategies of maintenance and factors affecting them.
• Prepare project engineers to work as maintenance engineers.
• Learn how to choose the appropriate maintenance strategy for the organization, whether in-house maintenance or contracted maintenance.
• Clarify types of maintenance contracts.
• Understand the requirements for contracts based on the FIDIC format.
• Prepare maintenance contract documents.
• Understand maintenance contractor strategies and how to deal with them.
• Evaluate maintenance tenders.
• Secure spare parts through maintenance contracts.
• Understand handover and site delivery in maintenance contracts.
• Develop specifications for purchasing maintenance management software.
• Evaluate available maintenance software and choose the most suitable one.
• Explore a sample maintenance software system.

Course Outline

Maintenance Concepts, Systems, and Organization

• Maintenance (concepts, objectives, tasks).
• Maintenance systems (technical and economic comparison study).
• Basics of choosing the optimal maintenance method.
• Modern maintenance organization based on its economic importance.
• Measuring maintenance effectiveness.
• Maintenance functions.
• Planned maintenance and its types.
• Organizing maintenance.
• Modern trends in maintenance management.

Effective Maintenance Management Principles

• Applying management techniques to maintenance.
• Work planning, scheduling, and work supervision.
• Performance measurement in maintenance.

Strategic Maintenance Planning

• Initial considerations.
• Developing strategic programs.

Maintenance Planning and Scheduling

• Principles of planning.
• Anticipating maintenance activity load.
• Prioritizing tasks.
• Developing plans.
• Scheduling principles.
• Coordination with equipment users.
• Scheduling tools.
• Using computers in maintenance scheduling.

Fault Analysis

• Definition of faults.
• Quantitative methods for fault analysis.
• Workshop on using Excel software to identify types of faults.
• Qualitative methods for fault analysis.

Maintenance Materials Monitoring and Spare Parts Management

• Types of spare parts and their classification.
• Organizing spare parts warehouses.
• Spare parts monitoring procedures and policies.
• Identifying spare parts needs.

Computerized Maintenance Management Systems (CMMS)

• Maintenance documentation and systems management using computers.
• Functions of CMMS.
• Benefits of using CMMS.
• Evaluating and selecting CMMS.
• Overview of CMMS software.

Downtime Management (Renovation, Renewal, and Maintenance Projects)

• Work planning, scheduling, and supervision during downtime periods for renovation, renewal, and maintenance projects.
• Requirements for downtime and renovation work.
• Detailed work structures.
• Critical path related to work planning and control.

Computer-Based Maintenance Management Systems

• Using computers in maintenance management.
• Understanding the required integration in CMMS.
• Discussing CMMS related to factory data, work order management, scheduling, preventive maintenance, performance reports, critical paths, and cost control.
• Developing operational specifications.
• Reviewing CMMS systems.

Implementing a Computerized Maintenance Management System

• Key aspects of CMMS.
• Inputs and data integration.
• Computer-based downtime planning.

Predictive and Preventive Maintenance Using Computers

• Preventive maintenance and its planning principles using computers.
• Preventive maintenance work planning, with practical applications on computers.
• Predictive maintenance (concepts and modern techniques).
• Equipment and tools used in predictive maintenance and criteria for their selection.
• Planning predictive maintenance and monitoring equipment status using computers.
• Differences between planning and scheduling for predictive and preventive maintenance.
• Costs and economic and technical returns of shifting from preventive to predictive maintenance.

Spare Parts Planning and Provisioning Using Computers

• Identifying spare parts orders for preventive and predictive maintenance.
• Monitoring spare parts inventory using computers.
• Determining optimal order sizes for spare parts to reduce inventory costs and minimize stockpiling.

Developing Maintenance Strategy Using Computers

• Developing a maintenance strategy and managing spare parts inventory.
• Analyzing historical CMMS data to improve reliability.
• Developing a computer-based maintenance strategy to maximize spare parts usage.

Using Pre-Configured Computer Programs in Maintenance

• Methods for selecting software used in maintenance operations.
• Analyzing maintenance-specific systems.
• Design principles for maintenance software.
• Workshop on demonstrating and working with maintenance software.

Performance Measurement Techniques

• Classifying equipment into elements.
• Suitable maintenance plans for each element.
• Equipment performance and determining plan effectiveness.
• Analyzing equipment failure rates.
• Adjusting plans to improve performance.
• Maintenance repair as an indicator of preventive maintenance effectiveness.

Monitoring Maintenance Operations

• Actual performance of maintenance operations.
• Comparing actual performance with planned performance.
• Reasons for discrepancies (from the maintenance department).
• Adjusting plans based on performance.
• Changes in plans as indicators of planning efficiency.

Financial and Accounting Performance Evaluation for Maintenance Management

• Consumables expenditure.
• Spare parts expenditure.
• Labor efficiency and utilization.
• Book values and actual equipment values as indicators of performance.
• Remainder inventory and methods for liquidation.

Target Audience for the Training Program

• Engineers and technicians working in the maintenance field.
• Maintenance managers and supervisors responsible for planning and overseeing regular and emergency maintenance operations.
• Engineers working in operational and maintenance projects.
• Facility and facility management specialists.
• Professionals responsible for evaluating maintenance contracts and technical procurement.
• Professionals working in inventory and spare parts management, interested in integrating computer technologies into their operations.
• Project managers and engineers.