Improving System Operational Success to achieve Safe and Profitable Operations
Course Instructor - V. Narayan BMech, DipEE, DIM (View Profile)
Course Outline
Why do we have safety or environmental incidents? Why do we suffer mission
failures or production shortfalls? Is there a relationship between maintenance
costs and system availability? Can you improve operational performance and reduce
maintenance costs at the same time? If you are a manager, supervisor, engineer,
logistics specialist an academic or other professional seeking an answer to any
of these questions, this workshop will be able to help you. It is aimed at
people with a stake in Operational Success working in Defence Services, Manufacturing
Plants, Chemical, Pharmaceutical, Oil & Gas, Railway, Paper Industries, Contractors
and other Service providers. You will learn ways to improve the performance of your
plant as a result of better reliability and availability of your facilities.
Effective maintenance is the key, not merely more maintenance. Investing effectively
in maintenance can help you to reduce the risk of HSE incidents, mission failures or loss
of production due to equipment unavailability. In this workshop, you will learn a logical
and structured approach to achieve your (organisation's) objectives.
Business success depends on how well we manage risk, so we begin with a discussion
of quantitative and qualitative risks. Human failures are more difficult to manage,
but they matter a lot, so we will address this subject in some detail. This leads us
to pro-active and reactive ways to improve equipment reliability. You will learn about
Root Cause Analysis, a powerful reactive problem-solving tool, and get a good
understanding of where and how to apply the method. On the pro-active side, we
will see how Reliability Centred Maintenance can help us plan our work and improve
our equipment reliability significantly. While you should not expect to become RCA
or RCM experts as a result of this workshop, you should certainly have a good
understanding of both, and know where to apply them.
Implementation of the results of analysis is of course the key to reaping the
benefits. Analysis is the easy bit; implementing the results always poses challenges.
So we will see how to grind away at the hard parts - writing new maintenance routines,
scheduling work, then doing it on time, recording history, and hopefully, getting
rewarded. Finally we will see how to implement change successfully. For this we need
to understand critical success factors, change management, the importance of good
communication and how to track progress. Sustained improvement needs a process to
hold the gains.
The structure and content of this workshop will help you formulate action plans that
can significantly improve safety, production, mission success and cost performance.
Workshop Preparation
We will send you a limited amount of pre-reading material. In order to reap the
maximum benefit from the workshop, we request you to go through this material, and
answer the questions by e-mail. Please bring some case examples of typical problems
that you face in your work situation where you feel the material covered in the workshop
may be of assistance.
DAY ONE
Introduction and Objectives
Factors affecting System operational success
Quantitative risk
Qualitative risk
Performance measurement
Data recording
DAY TWO
Human factors
Human error and its causes
Video and discussion
Learning from failures
Performance measurement
Problem solving process - Root Cause Analysis
DAY THREE
Planning for success
Understanding the nature of failure
RCM principles and methodology
Task-bundling
DAY FOUR
Preventive maintenance routines and maintenance management systems
Scheduling
Work execution
Compliance
Reward systems
Performance monitoring
DAY FIVE
Implementation
Reporting results
Lateral learning
Holding the gains
Workshop summary and closing
Problem solving process - Root Cause Analysis
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