Auditing Effectiveness of Maintenance, Reliability & Spares

Introduction

There are many types of maintenance audits; most are associated with auditing compliance with procedures in place. Maintenance Management Audits have been around since the late 1980s. They are sometimes called Benchmarking Audits or Gap Analysis.
In this workshop we will outline the many different types of maintenance audits including remote, in depth and fast track audits. The fast track approach is a powerful technique to assess the effectiveness of maintenance and reliability using a multi-disciplined team representing all functions related to maintenance.
During the workshop delegates will conduct a mini audit, so they can conduct the process in their own company.
We will also cover specific audits covering KPIs, CMMS, work processes resource utilisation audits and spares inventory parameters.

What You Will Learn

As a result of attending this workshop delegates will learn:

  • What are best practices
  • A structured approach to auditing maintenance
  • How to determine strengths and weaknesses
  • How to conduct different types of audits
  • How to audit work processes and make improvements
  • How to develop an effective action plan to start the improvement journey
Contents

Session 1: Introduction to Benchmarking & Auditing
Improvement cycle
Benchmarking
Different types of Audits
Definitions

Session 2: Developing a Best Practice Model
Building a model of excellence
Model variations used by major companies
Overview ISO 55000

Session 3: The Fast Track Audit
The fast track audit
Audit process using a multi-disciplined team
Scoring and evaluation methodologies
Sample questions and reports

Session 4: In-depth Audits
Conduct in-depth audits
Developing the scope based on the audit objectives
Interviewing techniques
Planning the audit

Session 5: Auditing Work Processes
Overview of the methodology
Planning the audit using the example of a CMMS work process
Identifying issues and implementing corrective actions
Class exercise

Session 6: KP3 Integrity Audits
Background to this integrity audit
KP3 elements and the appropriate regulations
Initial findings in the UK

Session 7: Maintenance Condition & Execution Audits
Maintenance Practices Audits
Electrical Equipment Audits
Rotating Equipment Audits
Maintainability Review Audits
TPM Audits
Case study - Gas Booster Stations

Session 8: CMMS System Audits
Objectives of the CMMS
Auditing CMMS effectiveness specifying the scope and planning what to look for
Where does it all go wrong – many examples will be shown

Session 9: KPI Audits
Scope of KPIs
KPI reporting process
KPI Reports - why they are typically not read
KPI dashboards
Case study - a Middle East Refinery and UK Major Oil and Gas Operator

Session 10: Reliability Management System Audits
Key features of a reliability management audit
Reliability and availability KPIs

Session 11: Auditing the Effectiveness of Current Inventory Parameters
Why a review is necessary
Introduction to inventory management theory
Auditing the effectiveness of current inventory parameters

Course Review and Delegates' Actions Plans

Training Methodology

PowerPoint slides. Delegates will learn by active participation during the workshop and through the use of exercises, case studies
Exercises using MS Excel and MS Access

Who Should Attend

Maintenance Managers, Engineers, Analysts
CMMS Key Users
Warehouse Managers & Supervisors
Project Engineers
Spares & Inventory Personnel