Course Overview

Basic Maintenance Best Practice

Maintenance Best Practice are critical for every successful individual and company. Qualified personnel would be expected to carry out these practices during their duty, starting with the first steps and building up to a fully functional maintenance organisation.

The purpose of equipment maintenance is to minimize costly breakdowns and ensure that machinery operates at its top functionality. By ensuring that equipment is properly maintained, machine failure is practically removed from the facility. Even routine visual inspections can save a facility time and money. Regular servicing of equipment and ensuring that worn machine components are addressed early not only extends the life of the machine, but also stops the risk of rework or scrap product caused by the production of out-of-spec material.

If a machine is behaving erratically or underperforming to the performance standard, a technician trained in these practices is able to pinpoint and repair the problem before it leads to defective products and loss in production hours.

Course Objectives

By the end of this training, participants will be able to:

• Understand the purpose of equipment maintenance.

• Identify the impacts of a lack of machine maintenance.

• Understand why equipment must be properly maintained and how to prevent the risk of rework or scrap product.

• Understand the components that are subject to wear and tear, and implement visual inspection as part of routine maintenance.

• Monitor spare parts consumption effectively.

• Analyse equipment failures to develop the frequency of preventive maintenance.

Who Should Attend

This training course is suitable for a wide range of professionals but will greatly benefit:

• Maintenance Managers

• Maintenance Engineers

• Maintenance Supervisors

• Maintenance Technicians

• Key leaders from Maintenance

• Maintenance Executives

Course Content

Module 1: Work Management

• What’s Involved in Manufacturing Equipment

• Identify, validate, and approve work

• Prioritize work

• Plan work

• Schedule work

• Execute work

• Document work

• Plan for Emergencies

• Analyse work and follow-up

• Measure work management performance

• Plan and execute projects

• Use information technologies effectively

• Manage resources and materials

• The future maintenance

Module 2: Wastes in Manufacturing Muda, Muri and Mura: The Wastes of Lean & How Much They Cost the Organization

• Waste of Motion

• Waste of Transportation

• Inventory Waste

• Waste of Waiting Time

• Overproduction Waste

• Waste of Defects and Rework

• Waste of Over Processing

• Waste of Mura

• Waste of Muri

• How to eliminate & reduce waste

Module 3: Workplace Organization

• 5S Concept

• Visual Management System

• Production Levelling (Heijunka)

• Visual Controls

• Push / Pull production System

• Value Stream Mapping (VSM)

• Process Mapping

• Introduction to Kanban System

• Manufacturing Just in Time

Module 4: Maintain Basic Equipment & Trouble Shooting Ensure Proper Maintenance Of Your Manufacturing Equipment

• Autonomous Maintenance (AM)

• Steps of Maintaining Basic Equipment

• Trouble Shooting

• Measuring Equipment

• Hand Tools

• Machine Tool Cutters

• Perform Periodic Tools Assessments

Module 5: Quality Awareness and 5S

• Quality Awareness

• Overview of the 5S Process

• 5S Applications at Workplace

• 5S Audit Checklist

Module 6: Root Cause Analysis (RCA) Set, Measure and Improve

• What is a root cause analysis?

• What is the process required to conduct an RCA?

• Tools and methods required for RCA

• Effective Problem Solving

• Cause and Effect Relations

• RCA Methodologies – Examples and Application