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Istanbul

Optimizing Equipment Maintenance & Replacement Decisions

ID  402

Maintenance Planning and Asset Management Training Courses

Optimizing Equipment Maintenance & Replacement Decisions

Istanbul

Hotel Name
Hotel Meeting Room

07 Apr 2025 : 11 Apr  2025

25 Hours

3450 USD

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Course-options

Training Details

Introduction

  • Is your equipment (fixed or mobile) failing before planned replacement?
  • Are you unable to execute maintenance tasks because spare parts are not available?
  • Have you made significant investment in CBM methods and tools but struggle to realize the benefit?
  • Do you have lots of data from oil analyses but still struggling to accurately predict your equipment breakdowns?
  • Do you know how to determine optimum asset life?
  • Are you struggling to justify the economics of asset replacement?
  • Are you having difficulties in deciding whether to rebuild or replace your equipment to minimize the life cycle costs?
  • Do you need to optimize your emergency spare requirements?

If you answer YES to any of the above questions, this seminar is for you.

Seminar Objectives

The objectives of the program can be summarized as follows:

  • To focus on the techniques of optimization – the single most important thrust of this learning program. Whether the decision is about work-crew sizes, or the replacement of component-parts or entire equipment units, the concept of making the very best, most optimal, decision will be the principal concern of the training program.
  • To equip the participating maintenance managers, planners and schedulers and engineers with the know-how to select the most appropriate analytical tools for their maintenance decision-making.
  • Reflecting the growing focus of industrial safety and the profusion of safety-related litigation – think of transportation accidents, chemical spills, and mining disasters – the program will show how safety objectives relate to the optimization models, and will underline the advantages of having a well-documented and rigorously-executed program of maintenance and replacement.
  • To introduce the critical decision-making topics that can make a significant difference to the in-service time of equipment, to the costs related to doing maintenance too often or too seldom, and the optimization of asset utilization.
  • To not only cover the classic need-to-know material in the area, but to acquaint the participants with leading-edge and on-the-horizon approaches that they will encounter in the near future.

Training Methodology

The seminar will combine presentations with interactive practical exercises, supported by numerous case studies. Delegates will be encouraged to participate actively in relating the methodologies and tools presented during the 5-day course to the particular needs of their workplace.

Organisational Impact

Focus on the most advanced techniques for Maintenance Optimization

  • Select the most appropriate Analytical tools for maintenance decision making
  • Relate Safety objectives to optimization models
  • Introduce Critical Decision-Making Topics
  • Acquaint with Leading-Edge and On-The-Horizon approaches
  • Continue to Apply the Course-Learning to your workplace problems
  • Equipment maintenance and replacement decision are frequently based on informed opinions or subjective responses to common situations. In this course, we will deal with procedures based on careful research that is firmly rooted in reality. The course is intended to give you the tools needed to make data-driven decisions, which you can apply in your own environment and upon which you can rely to help you in developing appropriate programs. With so much data available, we often find ourselves in the bewildering position of being data – rich but information poor. We may have all the raw data we’ll ever need at our fingertips; but unless we can interpret and integrate it properly, it is of little use. To refine this data into useful information, we need the appropriate tools.
  • This course is designed to give you those tools. Our time is limited, and our individual interests and concerns vary. So we may not solve your particular problems in this course. However, I hope it will at least provide you with the concepts and techniques you need to address problems that arise as you carry out your responsibilities.
  • Engineers
  • Professionals of Plant operations
  • Facility Professionals
  • Mechanical, Maintenance and Operation Supervisors
  • Maintenance or Reliability professionals who are responsible for maintaining and managing the physical equipment assets of a Plant/Facility

Who Should Attend?

The ideal candidate for this seminar is an Engineer, Professional of Plant operations, Facility Professional, Maintenance or Reliability professional who is responsible for maintaining and managing the physical equipment assets of a Plant/Facility. He or she represents large Facilities and Plants from industries such as Oil and Gas, Petrochemical and Fertilizer, Pulp and Paper, Cement and Ceramics, Power Generation and Utilities, Primary Metals, and Heavy Manufacturing and Facilities.

Programme Outline

Day 1 – Physical Asset Management & Reliability Concepts

From Maintenance Management to Physical Asset Management

  • Challenges of physical asset management

  • The maintenance excellence pyramid

  • Reliability through the operator: Total Productive Maintenance

  • Reliability by design: Reliability Centered Maintenance

  • Optimizing Maintenance & Replacement Decisions

 

Reliability Improvement through Preventive Maintenance

  • Analysis of Component Failure Data

  • Probability Density Function

  • Reliability Function

  • Hazard Function

  • Weibull Density

  • Infant Mortality

  • Bath-Tub Curve

Exercise in Analysing Component Failure Data Using the Weibull Distribution

 

  • Estimating the Weibull Parameters

  • Using Median Rank Tables

  • The role of the RelCode software Package

Dealing with Censored Data, the 3-Parameter Weibull, and the Kolomorgov-Smirnov

Test

  • Upper-End Censoring, Multiply Censored Group Data

  • Estimating the Location Parameter in the Weibull Distribution

  • Checking the Goodness-of-Fit of the Distribution

 

Day 2 – Reliability Improvement through Preventive Maintenance (continued)

  • Component Replacement Procedures including Glasser’s Graph

  • Block Replacement Policies

  • Age-Based Replacement Policy

  • Setting Policies based on Safety Constraints, Cost-Minimization and Availability-Maximization

  • Repairable systems

 

Case Studies in Component Preventive Replacement

  • Including boiler plant, bearings, pumps, sugar feeds, compressor valves, and centrifuges

 

Spare parts provisioning

  • Fast moving spares

  • Emergency (insurance) spares

 

Case studies in spares provisioning

  • Including line replaceable units (LRUs), cylinder heads, repairable conveyor electric motors and utility transformers

 

Group and individual exercises

 

Day 3 – Reliability Improvement through Inspection

Inspection Frequency and Depth for equipment in continuous operation

  • Inspection Intervals to Maximize Profit

  • Maximizing Equipment Availability

  • Inspection Intervals for Equipment Used in Emergency Situations (e.g. protective devices)

  • Case studies including oil and gas field equipment such as pressure safely valves (for protective devices)

 

Health-Monitoring Procedures

  • Proportional Hazards Modelling

  • Spectroscopic Oil Analysis Programs

  • Optimization of Condition-Based Maintenance Procedures

  • Role of software for CBM optimization

  • Case studies including food procession industry (vibration monitoring), pulp and paper and shipping equipment such as compressors (vibration monitoring) and diesel engines (oil analysis), turbines in an electrical generating station (pressure measurements)

 

Demonstration of software for optimizing condition-based maintenance decisions

 

Day 4 – Reliability Improvement through Asset Replacement

 

Aspects of Discounted Cash Flow Used in Capital Equipment Replacement Analysis

  • Estimating the Interest Rate Appropriate for discounting

  • Present-Value Calculations

  • The effects of Inflation in the Analysis

  • Calculating the Equivalent Annual Cost (EAC)

 

Economic Life of Capital Equipment

  • The “Classic” Economic Life Model

  • Before-and-After Tax Calculations

  • The Repair-vs-Replace Decision

  • Life-Cycle Costing

  • Technological Improvement

 

Case Studies in Capital Equipment Replacement

  • Including seamers in the food processing industry and combustion engines in the oil and gas sector

Group and individual exercises

Clinic: Hands-On Use of PC Software for Capital Equipment Replacement Analysis

  • Participants will solve pre-set problems

 

Day 5 – Effective Use of Maintenance Resources

 

Organizational Structure, Crew Sizes, Workshop Resource Requirements

  • Balancing Maintenance Costs against Plant Reliability

  • Establishing the optimal number of machines to have in a workshop

  • Resource Requirements Using Queuing Theory and Simulation

  • Utilization of Outside Resources

  • Lease-Vs-Buy Decision

 

Day 1 - Asset Cost Management Introduction

Maintenance & Reliability Best Practices are critical for every successful individual and company. This workshop delivers many practical and new Maintenance and Reliability Best Practices concepts and tools. You will discuss these concepts and practice using practical tools in case studies and discussion groups. The costs associated with equipment downtime and reduced production can be significant. Learning how to effectively manage all aspects of your industrial facility is a must.This workshop is a combination of instructor lead topic areas and class discussions. Interactive discussions will allow you to hear and learn best in class applications relating to maintenance planning and cost management strategies. You will have the opportunity to ask lots of questions in order to consider how best to apply these tools and techniques in your organization.

Day 2 - Laying the Groundwork

Maintenance & Reliability Best Practices are critical for every successful individual and company. This workshop delivers many practical and new Maintenance and Reliability Best Practices concepts and tools. You will discuss these concepts and practice using practical tools in case studies and discussion groups. The costs associated with equipment downtime and reduced production can be significant. Learning how to effectively manage all aspects of your industrial facility is a must.This workshop is a combination of instructor lead topic areas and class discussions. Interactive discussions will allow you to hear and learn best in class applications relating to maintenance planning and cost management strategies. You will have the opportunity to ask lots of questions in order to consider how best to apply these tools and techniques in your organization.

Day 3 - Applying the Value based Process

Maintenance & Reliability Best Practices are critical for every successful individual and company. This workshop delivers many practical and new Maintenance and Reliability Best Practices concepts and tools. You will discuss these concepts and practice using practical tools in case studies and discussion groups. The costs associated with equipment downtime and reduced production can be significant. Learning how to effectively manage all aspects of your industrial facility is a must.This workshop is a combination of instructor lead topic areas and class discussions. Interactive discussions will allow you to hear and learn best in class applications relating to maintenance planning and cost management strategies. You will have the opportunity to ask lots of questions in order to consider how best to apply these tools and techniques in your organization.

Day 4 - Ensuring the Continuity of the Value-based Process

Maintenance & Reliability Best Practices are critical for every successful individual and company. This workshop delivers many practical and new Maintenance and Reliability Best Practices concepts and tools. You will discuss these concepts and practice using practical tools in case studies and discussion groups. The costs associated with equipment downtime and reduced production can be significant. Learning how to effectively manage all aspects of your industrial facility is a must.This workshop is a combination of instructor lead topic areas and class discussions. Interactive discussions will allow you to hear and learn best in class applications relating to maintenance planning and cost management strategies. You will have the opportunity to ask lots of questions in order to consider how best to apply these tools and techniques in your organization.

The European Quality of Training and Management Consulting relies on advanced methodology in developing skills and enhancing the effectiveness of human resources. The company adopts modern methods to achieve these goals. In order to achieve its objectives, European Quality follows the following steps in a precise and professional manner:

  • Lectures and Visual Presentations:

    • Theoretical lectures are presented through PowerPoint presentations, videos, and short films, providing a comprehensive and enjoyable learning experience.

  • Scientific Assessment:

    • Trainees are thoroughly assessed before and after the training program to ensure the desired objectives are achieved and to provide necessary guidance.

  • Brainstorming and Role-playing:

    • Innovation and problem-solving are encouraged through brainstorming sessions and role playing experiences.

  • Practical Cases:

    • Practical learning is emphasized through cases relevant to the subject matter and the nature of work for the trainees, contributing to the development of practical skills.

  • Final Evaluation and Certificates:

    • A comprehensive assessment is conducted at the end of the program. Trainees are awarded attendance and participation certificates recognized by the European Quality for Training and Administrative Consultations, provided they have completed at least 80% of the program days.

  • Training Materials:

    • Professional trainers and experts in various fields create scientific and practical training materials, which are printed and retained, and distributed on CD or flash drives to ensure easy access to the content.

  • Post-Training Follow-up:

    • European Quality for Training and Administrative Consultations provides continuous support after the training program. This support includes additional consultancy sessions or workshops to ensure the continuity of learning and the application of acquired skills in the working environment.

  • Customized Training Programs:

    • Training programs are designed to meet the needs of individual companies and institutions. Client needs are carefully analyzed to ensure that the training content aligns with their specific objectives and achieves the desired impact.

  • Utilizing Technology:

    • Training incorporates modern techniques such as online platforms and distance learning to provide flexible and effective learning experiences. Participants can access educational resources online and engage in discussions and online workshops.

  • Specialized Trainers:

    • Trainers and lecturers are carefully selected to ensure they have high expertise in their fields. Experience and professionalism are added to the training to ensure the delivery of high-quality content and effective learning experiences.

  • Encouraging Participation:

    • European Quality encourages active participation and interaction during training sessions. Interactive activities such as group discussions and collective exercises are organized to stimulate effective participation in the learning process.

  • Focus on Personal Transformation:

    • Participants are encouraged to think critically and develop problem-solving skills and decision making abilities. They are guided towards achieving personal and professional transformation, leading to improved performance in their work areas.

  • Continuous Assessment:

    • Continuous assessments are provided to evaluate participants performance and their understanding of the training materials. This assessment is used to modify the training program if necessary and ensure the desired results are achieved.

  • Terms and Conditions:

    • Terms and conditions apply to all training programs. It is assumed that registering for any training program implies the participants agreement to these terms, including registration, payment, and cancellation policies.

  • Prices and Discounts:

    • It is noted that the prices displayed on the website do not include a 5% value added tax. All prices are subject to discounts according to the companys policies.

European Quality of Training and Management Consulting reserves the right to change the location of the training program, change the accredited lecturers for program delivery, hold, or cancel the program in line with the companys vision and program conditions and our quality policy.

European Quality for Training and Consultancy is certified

ISO 9001-2015

All rights reserved

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12 Courses

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Maintenance Planning, Scheduling and Control

ID 17

One week

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Process Plant Optimisation & Energy Conservation

ID 21

One week

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Vibration Monitoring, Analysis, Alignment & Balancing

ID 23

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PORT MANAGEMENT AND OPERATIONS

ID 664

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Maintenance Strategy Development and Cost Effective Implementation

ID 717

Two weeks

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The Complete Course on Facilities Management

ID 158

One week

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Professional Maintenance Planner

ID 718

One week

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Economic & Technical Evaluations in Engineering & Maintenance

ID 237

One week

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Fundamentals of Asset

ID 239

One week

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Machinery Failure, Vibration & Predictive Maintenance

ID 241

One week

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Maintenance Planning and Asset Management

ID 586

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INTRODUCTION TO DATA MANAGEMENT FOR OPERATIONS

ID 588

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