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Improve Equipment Design,
Reduce Equipment Life Cycle Costs, Procure Better Assets
Practical 3 Day workshop (£950 plus VAT)
Contact us for next course dates.
 Click here for an EEM/Maintenance Prevention workshop brochure
Most managers and engineers have had experience of working with troublesome assets that need significant attention during routine operation. Perhaps even of assets that took months to get to the point were they can be used productively. Often this leaves a legacy of high levels of production manning to deal with the side effects of unpredictable performance, regular visits from maintenance technicians, more frequent quality checks and high levels of material “give away”/scrap allowances. In the widest sense, such assets are “high maintenance” with correspondingly high running costs.
Maintenance Prevention (MP) was developed from studies of the the pitfalls which result in organisations making the wrong choice about equipment and ending up with “High Maintenance” assets that cost more than expected, don’t work well and fail to deliver their full potential.
The result is a process for translating the shop floor reality into MP friendly design standards and a framework for managing the timely collaboration of skills and resources needed to deliver equipment and processes which have lower life cycle costs because they are
- Easy to use
- Easy to maintain,
- Intrinsically reliable
- intrinsically safe
Maintenance Prevention tools also enhance project value in terms of delivering equipment and working practices which:
- Are more flexibie to evolving customer needs/features
- Deliver higher levels of return on investment
- Are capable of achieving flawless operation from production day 1.
Also known as Early Equipment Management the technical gains from applying MP principles and techniques include
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Reduced levels of intervention during the production process leading to lower quality defects
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Extended asset life and lower energy and maintenance cost per 1000 hours due to low rates of “accelerated wear”.
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Improved safety/human error performance due to easy to run processes which require less training,
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Simpler planning and coordination due to increased predictability of asset performance.
Other gains from applying MP principles and techniques include
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Improved cross functional collaboration leading to faster capital project delivery, enhanced customer value
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The capability to deliver innovative solutions on time under budget.
Why attend the workshop?
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The learning goals for the workshop are to help participants to:
- Understand what is Maintenance Prevention (MP), why it is important and how to apply MP principles.
- Collate and structure current knowledge and best practice to improve equipment design decisions;
- Analyse existing and proposed equipment to identify MP weaknesses and improve equipment design specifications;
- Incorporate MP standards and checklists into equipment specification, procurement and implementation programmes to reduce equipment life cycle costs and enhance project value.
- Develop customised plans to implement Maintenance Prevention principles and techniques into current project management/capital project processes.
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The content of the workshop was developed from our work with well known and award winning organisations, It provides a practical insight into how to build on improvement tools introduced during our Lean Maintenance, TPM and Lean Team Leader CI toolbox workshops. It also provides practical tools to enhance 6 Sigma, project management, plant upgrade and new product introduction processes.
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Delegates will take away a comprehensive workbook containing briefing notes and supporting templates so that they can apply MP tools back at the workplace.
Day 1:
Introduction
- Introduction to workshop/Learning goals
- What is Maintenance Prevention, why is it important
- Case study
- Assessing Asset MP status and improvement priorities
- Identifying weak components and improvement targets
- Equipment Management Projects, What goes wrong?
- Assessing/Designing MP friendly project management processes
Knowledge Management
- Collating tacit knowledge
- Developing MP design standards and accountabilities
- Setting triggers for Innovation
- Testing design concepts against MP standards
- Defining and addressing knowledge gaps
- Developing MP friendly high level design specs/evaluating procurement options
- MP Best practice design
Day 2
Delivering Equipment Design Excellence
- Life cycle cost modelling
- Prioritising critical decisions
- Understanding the new shop floor reality
- Stage gate planning, organisation and review
- Problem prevention
- Team roles and key decisions
- Working with vendors/win win alliances
- Quality audits
- Enhancing Project Value
- Value Engineering (Introduction to Lean Design and Design for Six Sigma)
- Operations design for low life cycle costs
Day 3
Delivering Flawless Operation
- MP, Operations and preventive maintenance working practices
- Training, skill development and standardisation to reduce finger trouble
- Commissioning, test runs and focussed improvement
- Technology transfer and documentation management
- Process Optimisation and continuous improvement goals
Implementing MP friendly practices
- Designing an MP programme
- Making MP part of your next project
Action Planning
- Developing the project vision
- Quality plan milestone design
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