The current economic downturn is causing problems worldwide. Corporate executives have to take immediate cost reduction measures. Since maintenance is perceived as an expense, it is high on the hit list. It is easier for senior management to take a slash and dash approach and mandate a corporate wide percentage based budget cut. However, this approach imposes a major problem on the maintenance department. The work load for maintenance usually doesn't reduce, except now they have fewer resources to accomplish the same.

This seminar will teach you how to sustain downsizing and do more, with less resources, all without sacrificing the quality of service provided by “Maintenance” to other departments. You can accomplish this by improving the work process flow, introducing or improving planning/scheduling and introducing appropriate technologies where applicable such as computerized maintenance management, mobile, barcode and RFID. These efforts have a proven track record of improving maintenance productivity by 30-50%.

As global competition intensifies, corporate executives are adopting new concepts and technologies to increase productivity and quality. Yet, many overlook the most important operational support system - the maintenance organization. While maintenance is traditionally underutilized, proactive organizations are increasingly recognizing the impact of maintenance on increased equipment availability and utilization, on increased quality, and thus on resultant competitiveness and profitability. Maintenance is becoming a focus for competitive advantage.

Operational organizations must start viewing maintenance as a resource center, rather than a cost center. In a world class organization, maintenance is a force for profit that:

• Contributes to Total Quality Management
• Increases Utilization of Critical Assets
• Improves Plant/facility and Maintenance Productivity
• Increases Service to Other Departments

• Plant Engineers
• Maintenance Supervisors and Managers
• Industrial and Manufacturing Engineers
• Plant and Facilities Managers
• Directors of Operations
• Maintenance Planners
• Maintenance Schedulers
• Purchasing/Store Managers
• Inventory Related Managers
• Other professionals involved in Maintenance Management

• Not just a seminar
  Unlike many other programs, you won’t leave this one just having heard ideas and principles. Instead, you will develop specific actions to be implemented as soon as you return to your job.
• State of the Art
  Related state of the art technology is discussed and presented.
• Specially Designed Exercises
  An integral part of the course, exercises provide a means of understanding the material covered, and is designed to help you make a continued, future use of seminar content.

Work Process Flow
It is important to map out the most efficient work flow that maintenance should follow. The flow must be created through a team effort so that all buy in the process. While determining the optimum flow, you will discover:

• Unproductive work
• Unnecessary delays
• Underutilization of people
• Ineffective data management

How to Optimize your Preventive Maintenance (PM) Program

• Audit to make sure PM tasks being performed are effective
• Eliminate PM waste
• Optimize PM frequencies

How to Minimize Unplanned Repairs

How to Optimize Parts & Tools in Inventory

• Minimize Obsolete inventory
• Reduce Excess inventory
• Optimize ROP, EOQ, Min-Max
• Implement ABC Analysis
• Shorten Lead time
• Work with suppliers to minimize stock

Effective Planning and scheduling
To maximize the efficiency of maintenance personnel, it is important to have effective planning and scheduling in place. Planning includes:

• Detailed job steps
• Safety requirements (permits etc.)
• Parts, Labor skills, Tools requirements
• Information (Drawings, sketches. Documents etc.)

Scheduling functionality is to make sure labor and Equipment/Facility are available when needed and set appropriate job priorities.

Computerized Maintenance Management System (CMMS) Efficiencies

• How to use your CMMS effectively for your application
• How to handle compliance issues effectively
• How to save money by interfacing your computerized maintenance system with other systems such as a Building Control System, Vibration Analysis etc.
• Link with O/M manuals and CAD drawings

Mobile Computing (with bar code/RFID if applicable)
Mobile computing technologies can provide enormous advantages to field technicians, who need portable access to facilities and maintenance information with ease.

By significantly reducing paper based and voice based communication between the field and the office, mobile computing results in rapid response time in the field, enabling direct access to critical data and elimination of time consuming paper work and data entry. Mobile technology can offer the following functionalities:

• Equipment
  • Rounds and Readings
  • Inspection/Checks
• Preventive Maintenance
• Labor and Material Control
• Work Order System
• Parts Inventory Management

Performance Metrics
The goals of maintenance activities should coincide with the overall organization's goals. Proper metrics should be defined and monitored. Some examples of maintenance metrics:

• % Planned Maintenance
• % PM compliance
• Backlog
• Overtime %

Root Cause Analysis
Equipment/Asset failure must be analyzed. Finding the root cause is first step to being able to prevent it in the future.

• Improve Maintenance Productivity
• Improve Asset Performance
• Reduce Down Time
• Monitor and Improve Employee Productivity
• Reduce Outside Contract Work
• Provide Better Service to Other Departments
• Monitor/Control Maintenance Costs
• Reduce Clerical Costs
• Develop effective problem solving skills
• Increase Overall Productivity & Profits

A variety of instructional methods will be used to make an adult learner an active participant rather than a passive observer. Instructional methods primarily include: lecture, discussions, hands on exercises and demonstrations.

Workshop Materials:

• Handout Material: Articles and case studies
• Visual Aids: Power Point Presentation
  

• Professional Engineer (PE)
• Certified Plant Engineer (CPE) by Association of Facilities Engineering (AFE)

• Authored a book, “CMMS made easy” published by McGraw-Hill 
• Authored a book entitled “Microcomputer Aided Maintenance Management System” published by Marcel Dekker, Inc.
• Authored a book entitled “How to Select and Justify Manufacturing Software”
• Authored a chapter in “Evolution of Computerized Maintenance Management” in the “Encyclopedia of Microcomputers”, published by Marcel Dekker, Inc.
• Authored a chapter in “Materials Handling Handbook” published by John Wiley and Sons.
• Authored several technical articles published by various journals.

• Train all personnel at one time in one location
• Seminars can be customized to focus on the needs of the company
• Encourage cooperative problem solving
• Employees spend less time away from job and less travel expenses
• Lower costs per employee with increased productivity
• Key personnel stay on-site
• Programs presented by recognized experts in the field of CMMS