Technical Workshop Series
Advanced Maintenance Strategy
Know Your Trainer
B Tech from IIT Roorkee, PGDM from IIM
Calcutta and is an Ex IES officer with
intensive experience in various sector. He is
a certified Lean Six Sigma Black Belt
Trainer
He has helped manufacturing companies
turn-around by implementing
Manufacturing Excellence , Six Sigma,
TPM, TQM, Mfg Strategy and New Product
Development & Breakthrough Innovation
He is a passionate reader and have
inclination to solve complex business.
Who should attend
Department Head
Quality Professional
Maintenance Professional
Project Management Professional
Plant Engineering
Innovation Manager
Management Representative
© Tetrahedron Manufacturing Services Pvt Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Developing a World-Class
Maintenance Practice is one step
towards Business Excellence.
Advanced Maintenance Strategy can
help you to maintain core disciplines,
drive improvement, identify best
practices, develop a maintenance
organisation, effective failure
management and program
development.
Benefits of attending
This session will help the participants to
1. Identify planning best practices and key
elements for taking action on them
2. Understand how world-class organizations solve
common planning problems
3. Evaluate your practices compared to those of
others
4. Improve the use of your information and
communication tools
5. Improve productivity through use of better,
more timely information
6. Create and preserve lead-time in work
management and use it for planning and
scheduling resources
7. Improve consistency and reliability of asset
information
8. Optimize preventive and predictive maintenance
strategies
9. Audit your maintenance operations
10.Use the results to develop and improvement
strategy
11.Establish Auditing and Performance Indicators
as a key element of the maintenance strategy
Technical Workshop Series Tetrahedron Academy

Workshop Agenda
Introduction to Advanced Maintenance Safety in maintenance
a. Maintenance in the Business Process a. Myths about safety
b. Objectives of maintenance management b. Why the concern for safety
c. Evolution in Maintenance Management c. Unsafe acts and unsafe conditions
d. The Maintenance Management Environment d. Safety culture elements
and the need for improvement e. Conducting safety audits
e. Maintenance life cycle Basic Maintenance to Adv Maintenance
f. Common maintenance management problems
g. Typical responsibilities of a maintenance Condition Monitoring
manager a. Visual Monitoring
h. The maintenance organization b. Performance Monitoring
i. Structure and content of Maintenance c. Monitoring of Vibrations and Noise
Management Strategy d. Monitoring of Wear Debris
e. Heat Monitoring
Maintenance Policies and Strategies Two Important CM Techniques: Analysis of
Introduction Vibrations and Lubricating Oil
Reliability-Centred Maintenance a. Analysis of Vibrations
The Principles and Phases of RCM b. Analysis of Lubricating Oil
Total Productive Maintenance c. Advantages and Applications
Maintenance Strategies d. The Parameters Monitored
a. Breakdown Maintenance e. The Definition of Alarm Thresholds and Oil
b. Preventive Maintenance Sampling Methods
c. Predictive Maintenance f. Oil Analysis Techniques
d. Proactive Maintenance g. Monitoring of Lubricant Properties
The Choice of the Most Opportune Strategy Information Technology to Support of CM
The Maintenance System Soft Computing Technologies for CM
a. Maintenance Management Testability and Prognostics
b. Programming of Maintenance
c. Performance of Maintenance
Testability
a. Testability Figures of Merit
d. Maintenance Engineering
b. Management of Testability
The Movement of Maintenance Management
Prognostics
Towards the Services Economy a. Prognostics and Availability
a. Subcontracting
b. Logistical Parameters Correlated to Prognostics
b. The Establishment of External Companies
c. The Figures of Merit of Prognostics
c. Outsourcing
d. Testability Figures of Merit Applicable to
Facility Management Prognostics, Implementation of Prognostics
The Global Service of Maintenance e. The Process of Prognostics Planning

Maintenance planning and control Maintenance Auditing & Improvement

a. Introduction to Maintenance Auditing and
a. Maintenance work flow process
Benchmarking
b. Work requests and work orders
b. The Maintenance Auditing Process
c. Work planning and scheduling
c. Maintenance Auditing Methodology
d. Backlog management
d. Conducting a Maintenance Audit
e. Resource management
e. Interpreting Audit Results
f. Spare parts management
f. Using Auditing and Benchmarking to drive
g. Maintenance master budget
improvement
h. Capital budgeting
i. Maintenance initiatives Performance Indicator & Mgmt Reporting
j. Replacement analysis of assets Managing and Measuring Progress to Excellence
k. Maintenance operating budget Information and Control, Management Levels and
l. Innovation and creativity Information, Maintenance Performance Indicators
Management Reports, Continuous Improvement in
Maintenance,

© Tetrahedron Manufacturing Services Pvt. Ltd

Phone : +91 7042140046 Email : training@tetrahedron.in
 Technical Workshop Series
Reliability Centered Maintenance ( RCM)
Know Your Trainer
B Tech from IIT Roorkee, PGDM from IIM
Calcutta and is an Ex IES officer with
intensive experience in various sector. He is
a certified Lean Six Sigma Black Belt
Trainer
He has helped manufacturing companies
turn-around by implementing
Manufacturing Excellence , Six Sigma,
TPM, TQM, Mfg Strategy and New Product
Development & Breakthrough Innovation
He is a passionate reader and have
inclination to solve complex business.
Who should attend
Department Head
Quality Professional
Maintenance Professional
Project Management Professional
Plant Engineering
Innovation Manager
Management Representative
© Tetrahedron Manufacturing Services Pvt Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Companies overall profit is driven
directly by the up-time of all
equipments, devices and instrument.
RCM helps company to reduce the
downtime and unavailability to
maximum extent and help people to
conduct reviews of overall health of
all equipment and make plan for
corrective action in case required.
Benefits of attending
This session will help the participants to
1. Understand the effect of maintenance activity
in overall performance of organization
2. Conduct the failure analysis and train other on
the same
3. Conduct FMEA with maintenance perspective
4. Conduct COFA and develop logic tree
5. Prepare for RCM implementation
6. Determine design change required and
communicate the same
7. Develop Preventive Maintenance (PM)
worksheet and execute it
8. Conduct maintenance of Devices and
instruments
9. Measure and Monitor RCM performance
The delivery method will be combination of
theory, examples, case study, group work and
individual exercise during the session. Also based
on the session progress and intensity there will be
some fun learning elements to break monotony.
The faculty will facilitate the workshop by visually
appealing power-point and videos where ever
required
Technical Workshop Series
Workshop Agenda
Session 1 Introduction to RCM
The Changing world of Maintenance
I. Maintenance and RCM
II. A No-Nonsense Approach to RCM
III. RCM as a Major Factor in the Bottom Line
Session 2 Fundamental RCM Concepts
I. Understand the Three Phases of an RCM-Based
Preventive Maintenance Program
II. Know what are the Three Cornerstones of RCM-Single-
failure analysis, Hidden-failure analysis, Multiple-
failure analysis
III. Understand the Missing Link: Potentially Critical
Components, Commitment Components, Economic
Components
IV. What is “Canon Law “of Run-to-Failure Components
V. Integrate of Preventive and Corrective Maintenance
VI. What is the Anatomy of a Disaster
VII.How to Find the Anomalies,
VIII.Understand Component Classification Hierarchy
Understand different RCM analysis Processes:
FMEA,FMECA and COFA
Session 3: RCM Implementation: Preparation
Preparation needed before RCM implementation
i. Comprehensive Equipment I.D.Database
ii. Informational Resources
iii. Establishing Convention
iv. The COFA Excel Spreadsheet versus the FMEA
v. The PM Task Worksheet
vi. The Economic Evaluation Worksheet
Session 4 : Implementation Process-Phase 1
Implement RCM through COFA Worksheet with the
COFA Logic Tree, the Potentially Critical Guideline,
and the Economically Significant Guideline
i. Describe the Component Functions
ii. Describe the Functional Failures
iii. Describe the Dominant Component Failure Modes for
Each Functional Failure
iv. Is the Occurrence of the Failure Mode Evident?
v. Describe the System Effect for Each Failure Mode
vi. Describe the Consequence of Failure Based on the
Asset Reliability Criteria You Selected
vii.Define the Component Classification
How to implement RCM through FMEA/FMECA
i. Determine System Boundaries
ii. Determine Subsystem Boundaries
iii. Determine Interfaces , Determine Functions
iv. Determine the Functional Failures
v. Determine Equipment Responsible for Failures
Case Study: Averting a Potentially Devastating Plant
Consequence
© Tetrahedron Manufacturing Services Pvt. Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Session 5: Implementation Process-Phase 2
How to do PM Task Selection Process
i. Understanding Preventive Maintenance Task
Terminology
ii. Condition-Directed, Time-Directed, and Failure-Finding
Tasks
iii. The PM Task Worksheet
iv. The PM Task Selection Logic Tree
v. Why a Condition-Directed Task Is Preferred
vi. Determining the PM Task Frequency and Interval
vii. Is a Design Change Recommended?
viii.Completing a Typical PM Task Worksheet
ix. Institute Technical Restraints
x. A Sampling Strategy
xi. Common Mode Failures
xii. Different Predictive Maintenance (PdM) Techniques
Vibration Monitoring and Analysis , Acoustic
Monitoring, Thermography or Infrared Monitoring
Oil Sampling and Analysis, X-ray or Radiography
Inspection, Magnetic Particle Inspection
Session 6: RCM for Instruments-Phase 3
Instrument Categories
Instrument Design Tolerance Criteria
The Instrument Logic Tree
i. Instrument Is Analyzed in the COFA Worksheet and
the PM Task Selection Worksheet.
ii. A PM Is Required. Calibration Criteria and Periodicity
Guidance Are as Follows.
iii. Were the Last Three Successive Calibrations Within
Vendor Tolerance Criteria?
iv. Periodicity Extension Is Allowed.
v. Reduce Periodicity or Implement a Design Change.
vi. Is an Indication Comparison Applicable?
vii. Is the Consequence of Excessive Drift Acceptable?
viii. Were the Last Two Successive Calibrations Within a
+/−2.5 Percent Accuracy Tolerance?
ix. Periodicity Extension Is Allowed.
x. Were the Last Two Successive Calibrations Within a
+/−5.0 Percent Accuracy Tolerance?
xi. Periodicity Extension Is Not Allowed.
xii. Reduce Periodicity or Implement a Design Change.
Session 7 :Monitoring & Trending - Phase 4
Measuring Reliability & Aggregate Metrics
Unplanned Plant or Facility Trips, Capacity Factor,
Unplanned Operator Actions, Unplanned Power
Reductions, Production Delays, Enforcement Actions,
Litigation Occurrences, Citations and Violations, Root-
Cause Evaluations, Injuries, Rate of Written CMs, Overdue
CM Backlog, Overdue PM Backlog, Weighting
Factors,Performance Calculations and Performance Graph
by System, Avoid Reliability Complacency, How to
Maintain Your Reliability Performance
 Technical Workshop Series
Modern Maintenance & Reliability Management:
Planning and Estimating Maintenance Planning and Scheduling
Know Your Trainer
B Tech from IIT Roorkee, PGDM from IIM
Calcutta and is an Ex IES officer with
intensive experience in various sector. He is
a certified Lean Six Sigma Black Belt
Trainer
He has helped manufacturing companies
turn-around by implementing
Manufacturing Excellence , Six Sigma,
TPM, TQM, Mfg Strategy and New Product
Development & Breakthrough Innovation
He is a passionate reader and have
inclination to solve complex business.
Who should attend
Department Head
Quality Professional
Maintenance Professional
Project Management Professional
Plant Engineering
Innovation Manager
Management Representative
© Tetrahedron Manufacturing Services Pvt Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
is one of the most important
elements in modern maintenance
management. Maintenance Planning
and Scheduling is also synonymous
with control of maintenance. In order
for maintenance planning and
scheduling to work many other
systems need to work well. Most
importantly equipment inspections
through preventive maintenance.
Benefits of attending
This session will help the participants to
1. Demonstrate the bottom -line benefits of
Maintenance Planning and Scheduling as a core
business process
2. Perform the critical steps in the identification of
necessary maintenance work
3. Develop a proactive maintenance planning system
to reduce costs, downtime and backlogs
4. Achieve streamlined maintenance processes by
developing a fool-proof scheduling program
5. Analyze work requests using a risk-based approach
so only necessary work is performed
6. Apply proven performance measurement tools
tailored to your maintenance conditions in order to
guarantee the successful execution of maintenance
work
7. Develop an accurate and reliable maintenance
history through tracing and analyzing maintenance
8. Improve turnaround performance by applying
proven best practices
9. Utilize best practice performance management in
order to control your Maintenance Planning
10.Effectively decrease downtime by coordinating and
streamlining your Maintenance Planning,
Scheduling and Control Process
Technical Workshop Series Tetrahedron Academy

Workshop Agenda
1-Modern Maintenance Management Routine Restoration and Discard Tasks
Practices as a Business Strategy Routine Condition-Based Tasks
a. Maintenance in the Business Process Failure-Finding Tasks
b. Objectives of maintenance management The Application of RCM in the Development of
c. Evolution in Maintenance Management Failure Management Policies
d. The Maintenance Management Environment and the Implementing Failure Management Policies
need for improvement 5-Work Planning, Scheduling and Control
e. Maintenance life cycle
Planning and Controlling Maintenance Materials
f. Common maintenance management problems
a. Accurate Inventory Status and Effective Parts
g. Typical responsibilities of a maintenance manager
Procurement Lowers M TTB (Mean Time to Repair)
h. The maintenance organization
and Total Costs
i. Structure and content of Maintenance Management
b. Considerations in Inventory Decisions
Strategy
c. Economic Order Quantity (EOQ)
2-Maintenance Policies &Logistics Planning d. Total Material Cost
a. Equipment Classification and Identification e. Definition of Notifications, Defects, Deviations
b. Maintenance Management Policies f. Notification Process, Roles and Principles
c. Equipment Criticality Grading g. Weekly Master Schedule
d. Job Record Policy i. Define Total Maintenance Requirements
e. Principles of Work Order Design (Backlog) to Top Leaders
f. Maintenance Work Prioritization ii. Master Schedule Objectives
g. Logistic Support Analysis iii. Categorizing the Outstanding Workload
h. Maintenance Work Estimating iv. Determine Resource Availability
i. Maintenance Levels v. Determine Equipment Non-Utilization Profile
j. Support Documentation vi. Develop Draft Master Schedule
k. Support Equipment vii.Conduct Master Schedule Review Meeting
l. Maintenance Logistics Planning viii.Final Master Schedule and Implementation
3-Predictive and Condition-Based ix. Backlog Management
Maintenance (PM-PdM-CBM) 6-Controlling Maintenance Work
a. Understanding PM-PdM-CBM Areas of Application Measuring Performance, Sources of Data
b. Integrating Risk Based Maintenance (RBM) into Work Backlog Indices, Schedule Compliance
on Critical Assets PM and Emergency Indices, Productivity
c. Implementing a PM-PdM-CBM Program Indicators
d. Establishing Effective Scheduling Process 7-Information & Performance Management
e. Breaking a Facility Into Logical Parts and Level
Planning and Scheduling of Major Maintenance WOs
Loading of PM-PdM-CBM
f. Developing an Equipment List and using Modern and Shutdowns
Identification Techniques Planning and Scheduling, Work Breakdown
g. Writing PM Task Lists and Having Continuous Structure, Critical Path Method (CPM), Resource
Updating/Review Scheduling and Leveling, Safety in Maintenance
h. Documenting and Validating Results of PM-PdM-CBM Safety Audit
4-Review of RCM for Planner/Schedulers 8-Life Cycle Cost of Equipment
a. Capital Budgeting, Accounting Rate of Return
Failure Modes, Effects and Consequences
(ARR), Payback Method
Equipment Functions and Performance
b. Net Present Value Method (NPV)
Standards
c. Replacement Analysis of Equipment
Functional Failures
d. Performance Indicators
Failure Modes & Failure Effects
e. Workload Performance Indicators
Consequences of Failure
f. Planning Performance Indicators
Failure Management Policies
g. Effectiveness of Performance Indicators
Age Related Failure Patterns h. Cost of Performance Indicators
Random Failure Patterns
Management Reports

© Tetrahedron Manufacturing Services Pvt. Ltd

Phone : +91 7042140046 Email : training@tetrahedron.in