Maintenance Management Level 2

Preventive, Predictive Maintenance (PPM), TPM and Advanced Spare parts 3-day

Benefits from this course:

  • Our promise for this program is that your staff will have a detailed understanding of preventive and predictive maintenance and TPM (Total Productive Maintenance) including how to set it up, design task lists and implement the system. This understanding will lead to reduced breakdowns, reduced interruptions and improved customer service.
  • In predictive maintenance (PdM) students will be introduced to the various technologies.
  • PM has always been the best method of preserving assets. Whether you maintain factories, buildings or fleet the PM system can be the core of the proactive effort.
  • There is much to know to design effective PMs for different types of equipment. This course will, in a short time, bring an entire department to a deeper understanding of how to make PM and PdM more effective.
  • Course Agenda Day 1:
  • Understanding PM (Preventive Maintenance)
  • What is PM?
  • Understanding what PM is supposed to accomplish and the critical wear point
  • Appropriate PM strategy for the 3 equipment life cycles and 6 failure modes
  • Maintenance improvement curve- get the most bang for your buck
  • Justifying PM and PdM expenditures
  • Some benefits of PPM
  • What is the real cost of breakdown?
  • Selling PM/PdM
  • Benefits of PM/PdM
  • Install a PM/PdM System

Course Agenda Day 2:

  • Four types of task lists
  • TLC-Tighten, Lubricate, clean
  • Access to equipment
  • Interruptive verses non-interruptive
  • PM frequency and its effect on breakdown
  • PM frequency and the P-FF curve
  • Common tasks
  • Staffing the PM effort Strategies to PM and PdM done
  • Steps to install
  • Survey instructions
  • PM and PdM systems increase professionalism
  • Guidelines for involvement with predictive techniques
  • Oil analysis
  • Vibration analysis
  • Temperature measurement
  • Ultrasonic inspection
  • Advanced visual techniques
  • Other methods of predictive maintenance

Course Agenda for Day 3 introduces a new topic: Advanced Spare Parts and Storerooms

Our promise for this day is that your maintenance leaders and storeroom personnel will be conversant with the techniques and procedures of effective storeroom management and inventory control.

In maintenance of factories, fleets and buildings the parts and materials consume 40-70% of the budgeted dollar. Maintenance inventories can run millions of dollars. More so than the issue of paying for the inventory is the possibility of downtime and lost production from having the wrong inventory.

Techniques will be demonstrated to use the actual parts as pointers to areas ripe for cost reduction. Students will come away with an excellent overview of the issues of managing a maintenance storeroom and up-to-date techniques for dealing with these issues.

Agenda Day 3 (the day is designed around six major topic areas):

Vision and overview for the stockroom and the spares stored there

• World class maintenance and the inventory system to support it.
• Organizational set-up
• How the inventory and a stockroom fits into the big maintenance picture.

Some Basics

• What are the functions of the maintenance inventory?
• All of the terms defined
• Types and uses of inventory.
• Different categories mean different management strategies. Evaluate categories economically including Insurance Policy spares, capital spares, and consumables.

The Physical Stockroom

• Layout ideas to improve the storeroom
• Preservation, security and safety of materials

The Economic Stockroom

• Inventory control models
• True costs of maintaining a storeroom
• How to save money


• Inventory start-up including: parts catalog, parts numbering strategies, parts naming strategies
• Data necessary to manage the inventory
• Using the CMMS to manage inventory

Dealing with the Part itself

• Obsolete/redundant/surplus materials (reasons for obsolescence, how to minimize its impact, reason for surplus items, their identification and disposal action.)

• True cost of a spare part

• Standardization and codification

• ABC inventory management

• Rebuild verses new. Make verses buy, OEM verses make outside considerations.