Maintenance Optimising & Decisions Making Techniques

Duration - 2 days


In RCM studies, people frequently base maintenance task frequencies on MTBF. We will demonstrate that MTBF has no value in selecting task frequencies. Frequently maintenance is carried out too early or too late.
This 2-day workshop is concerned with making more informed decisions on when to carry out maintenance based either on costs or availability. We also cover life cycle approach decisions to evaluate alternative options.
Usually diagrams are shown in text books showing that if we do too much PM, it is costly and vice versa. We will demonstrate this concept with the aid of specialised off the shelf software.

What you will learn

As a result of attending this workshop delegates will learn:

  • The importance of understanding patterns of failures
  • How to optimise maintenance actions based on planned and unplanned costs
  • How to evaluate different strategies based on availability, e.g. RTF, Safe Life, Cost Effective Life and a PdM policy
  • How to analyse an existing maintenance strategy, including how to extract the data from the CMMS
  • How to optimise function testing of instruments using reliability data
  • How to use life cycle cost approaches to evaluate repair, upgrade or replace like for like


Session 1: Introduction to Replacement Decisions
Maintenance strategies
Principles of optimisation
Understanding life limiting characteristics
Evaluating RTF versus FTM versus PdM

Session 2: Approaches Used to Develop the Maintenance Life Plan
Maintenance Strategy Selection - the big picture
Overview of techniques for critical assets including RCM, FMEA, Reverse RCM
Understanding life limiting characteristics
Generic Maintenance Strategies

Session 3: Reliability Basics
Reliability theory to enable an understanding of different failure patterns
Probability plotting

Session 4: Optimising Replacement based on Costs
Determine optimum replacement intervals
Demonstration of how MTBF has little value in determining when to replace items
How to evaluate if PM is effective using historical data
Case study - petrochemical plant

Session 5: Optimising Replacements based on Availability
How to evaluate different maintenance strategies using RAM Modelling techniques
For different strategies, a review of the availability achieved, downtime, number of failures, etc

Session 6: Introduction to Repair versus Replace Decisions Using
How to make decisions based on life cycle costing
Different factors to consider
An 8 step approach to conduct an evaluation
Exercise: evaluate options for a bad actor

Session 7: Optimising Instrumented Protective Systems
The concepts behind evaluating function testing intervals for instrument trips using reliability data
Case study

Session 8: What is Reliability Growth Analysis (RGA)?
Introduction to RGA
Using reliability growth techniques to optimise overhauls

Who should attend

Managers, Engineers, Planners, who want to improve cost and equipment performance by optimising PMs and anyone responsible to develop PM strategies

Training Methodology

Delegates will learn by active participation during the seminar through the many exercises, examples and the use of software
Learning mediums will be PowerPoint presentations, case studies, exercises
Use of reliability analysis software (laptop required)