Reliability Centred Maintenance

25-26 Oct, 2018, Kuala Lumpur

FOCUSING ON
  • Introduction to RCM
  • Develop Equipment Block Diagram
  • Develop Phase 1 – Functions and Failure Modes
  • Develop Phase 2 – Conduct FMECA and Consequences
  • Develop Phase 3 – Determine Proactive Actions
  • Develop Phase 4 – Assessing PRPN & RRPN
OVERVIEW

Contrary to common believes that equipment failures are inevitable, many organizations in the aerospace and other industries have shown that with proper IDENTIFICATION, ANALYSIS, STRATEGY, zero failures are possible and can be achieved.

 

What we lack now is proper methodologies for achieving it.

 

Finding the root cause of a failure is important but what is more and very important is proactively eliminating the potentials of failures.

We must transform our reactive maintenance culture to that of proactive culture. We must Prevent failures before it strikes.

 

RCM with it’s concept of FMECA and failure consequences, identifies all potential failure modes whether it is visible or hidden, and proactively eliminates them before it occurs .

AFTER ATTENDING THIS COURSE YOU WILL RETURN TO YOUR JOB…
  1. Establishing asset functions.
  2. Establishing asset failures and failure modes.
  3. Conducting an equipment FMECA (S,O,D).
  4. Establishing failure consequences.
  5. Establishing RPN rating and ranking.
  6. Using the decision diagram for corrective action.
  7. Reassessing the potential RPN (PRPN).
  8. Finalising resulting RPN (RRPN).
WHO SHOULD ATTEND
  • Maintenance Managers
  • Maintenance Engineers
  • Maintenance Supervisors
  • Senior Maintenance Technicians
METHODOLOGY
  • Interactive Lectures
  • Explanations
  • Case Studies
  • Group Discussions
  • Q & A Sessions

    Since the subject requires real hands on practise , only some simple examples will be used to narrate the understanding and the phase progression.

    Participants are encouraged to bring sample failure incidences for discussion.

    Course Leader will provide the formats for phase 1 - 4 .
DAY 1
9:00 MODULE 1 : INTRODUCTION TO RCM
  • What is RCM?
  • The core of RCM
  • Brief history of RCM
  • 7 basics foundation questions of RCM
  • RCM is a five steps process
  • 4 phases of RCM implementation
  • How to measure equipment reliability
10:45 MODULE 2 : DEVELOP EQUIPMENT BLOCK DIAGRAM
  • List all main modules
  • List all sub-modules
  • Identify all failure potential components in every module
1:00 Lunch

2:00

MODULE 3 : DEVELOP PHASE 1 – FUNCTIONS AND FAILURE MODES

  • Determine function of components
  • Establish the performance standard for every component
  • Potential functional failures
  • Failure modes causing the failures
  • List all failure effects
5:00 End of Day 1
DAY 2
9:00 MODULE 4 : DEVELOP PHASE 2 – CONDUCT FMECA AND CONSEQUENCES
  • Understand severity, occurrence and detection
  • Rating methodologies for S, O, D consequences
  • Establishing the RPN
  • Failure consequences
  • Safety consequences
  • Environment consequences
  • Operation consequences
  • Non-Operation consequences
  • All hidden failure consequences
1:00 Lunch

2:00 MODULE 5 : DEVELOP PHASE 3 – DETERMINE PROACTIVE ACTIONS
  • Establish the failure mode ranking
  • Perform why? Why? For every failure mode
  • How to use the RCM design diagram
  • Brainstorm for permanent proactive actions
  • Test the solutions for effectiveness
3:45 MODULE 6 : DEVELOP PHASE 4 – ASSESSING PRPN & RRPN
  • Establish new potential S, O, D
  • Determine what to do, when to do
  • Clearly assign responsibility
  • Perform proactive task
  • Determine actual resulting RRPN
5:00 End of Course

 

LEARN FROM THE BEST

Mr. P. Balachandran brings to this course more than 17 years of solid industrial experience in the manufacturing sector as well as 12 years in maintenance manufacturing training and consultancy.

 

His experience includes that of Equipment Engineer, Section Head of Production, Production Manager and Training & Education Manager with well known corporations such as Motorola, Thomson Audio Electronics and Samsung Electron Devices.

 

Mr. Bala then became involved in management consultancy and trained full time in specific areas of manufacturing and maintenance training. His natural leadership style coupled with his vast industrial experience makes a valuable partner and resource in developing the workforce of the manufacturing sector and in trouble shooting.

 

Mr. Bala has trained more than 3000 professionals and some of the companies that have benefited from his expertise include Komag Malaysia, Minolta, Silitek, Sony Malaysia, Robert Bosch, TDK Malaysia, Swedish Motor Assembly, Western Digital, Dell Computers, Texas Instruments, TNB, Genting Sanyen, PROTON, Teck See Plastics, Hicom, Philips Semiconductor, Airod, B Braun, Carsem, Dynacraft, Seagate Industries, Mattel, Perodua, Johnson & Johnson and Malaysian Airlines System.

 

VENUE DETAILS

Furama Hotel Kuala Lumpur
136, Jalan Changkat Thambi Dollah
55100 Kuala Lumpur

Phone :03-2788 8888

 

IPA TRAINING IS REGISTERED WITH

 

CONTACT US

Juliany, 
O - 03 2283 6109,
M - 019 3134436
juliany@ipa.com.my 

Michelle, 
O - 03 2283 6100, 
M - 019 363 7822
michelle@ipa.com.my 

For Customised In-House Training
Yvonne,
O - 03 2283 6101, 
M - 012 2011247,

F - 03 2283 6108
 
yvonne@ipa.com.my
 

ADDRESS 

A-28-5, 28th Floor, 
Menara UOA Bangsar, 
No.5, Jalan Bangsar Utama 1, 
59000 Kuala Lumpur
www.ipa.com.my