INTRODUCTION FOR BASIC MAINTENANCE BEST PRACTICE 

Maintenance Best Practices are critical for every successful individual and company, qualified personnel would be expected to carry out during his 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, 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 behaving erratically, or underperforming to performance standard, that technician is able to pinpoint and repair the problem before it leads to defective products and loss in production hours.

KEY OBJECTIVES

• Understanding purpose of equipment maintenance
• The impacts of lack of machine maintenance
• Why equipment must be properly maintained or the risk of rework or scrap product
• Understanding the components that are subject to wear and tear, visual inspection must be part of routine maintenance
• Monitoring spare parts consumption
• Analysing equipment failures develop frequency of the preventive maintenance

WHO IS THIS TRAINING COURSE FOR?

This training course is suitable to 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 are Costing 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

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