Advanced systems for planning, controlling and evaluating maintenance and preventive maintenance by applying Kaizen and Lean theory with artificial intelligence methodology

Offline Price: SAR 2100

Course Duration: 5

Duration (Hrs) 30 Hours/Hours

Course date: 18/09/2022

Course Mentor: ESI

An introduction to the training course:

The technological explosion, economic competition, and knowledge growth were accompanied by a very significant development in industrial and administrative processes in all governmental and commercial sectors around the world, which made continuous improvement processes one of the most important conditions for the survival of organizations and the diversification of their competitiveness.

KAIZEN was an amazing discovery. The Japanese experience of continuous improvement, which the Japanese called KAIZEN, was able to achieve the lowest level of waste in operations, resources and time, achieving high rates of profits and financial returns, hence the interest in the Japanese philosophy of KAIZEN for the purpose of identifying and training it. And its application in the institutional and corporate sectors.

Planning, evaluating and controlling maintenance work is fundamental to business success. If the goal is to have a world-class organization, the maintenance strategy has a critical role to play in this task based on business objectives, and this strategy cannot be viewed as separate from other jobs, but rather as An integral part of a complete approach to high performance work.

This training course aims to identify the scientific methods for evaluating performance in the maintenance department, and to identify the modern methods and systems used in maintenance engineering, where the work and tasks entrusted to the maintenance department are listed. During the application of that knowledge, there should be feedback to address any defect in performance or to raise the effectiveness of work.

Course objectives: At the end of the course participants will be able to:

  • Understand and plan maintenance operations, types.
  • Gaining skills to improve maintenance work.
  • Preparing preventive maintenance plans and inventory control systems in order to raise the efficiency of maintenance work.
  • Increase equipment cycle times.
  • Reduce repair times.
  • Apply the best method for carrying out maintenance work.
  • Prepare and reduce preventive maintenance.
  • Spare parts inventory control.
  • Choosing and applying the correct and appropriate maintenance for the facility.
  • Planning and organizing maintenance work.
  • Preparing and following up a preventive maintenance plan.

Target groups:

  • Managers and supervisors in the maintenance and technical management sectors.
  • Managers, heads of administrative departments and those responsible for the operation and maintenance department.
  • All engineers, technicians and everyone involved in maintenance, production and operation.
  • Decision makers and makers.
  • Business owners in the areas of production, procurement, maintenance and technical support.
  • Anyone who finds himself in need of this course and wants to develop his skills and experience.

Course content

Unit One: Maintenance Philosophy

  • Define maintenance.
  • Duties and responsibilities of the maintenance department.
  • Organizing the maintenance department.
  • Types and methods of maintenance.
  • Maintenance planning and design.
  • Maintenance “Curriculum and Foundations”

Unit Two: Maintenance Management

  • The concept of maintenance.
  • The importance of maintenance.
  • Concepts of reliability and maintenance.
  • Methods of increasing the intervals between failures.
  • Methods to reduce repair times.
  • Maintenance methods.

Unit Three: Types of Maintenance

  • Malfunction maintenance.
  • Time based preventive maintenance.
  • Condition dependent preventive maintenance.
  • Corrective maintenance.
  • Preventive maintenance.
  • Prepare a preventive maintenance plan.
  • Determine equipment and devices.
  • Prepare daily maintenance card.
  • Determine weekly, monthly and quarterly maintenance dates.
  • Preparing the timing plan for the implementation of maintenance work during the year.

Unit Four: Spare Parts

  • Spare parts inventory management.
  • The importance of spare parts inventory.
  • Methods for determining the quantities required to be stored.
  • Spare parts inventory control methods.
  • Maintenance evaluation.
  • Maintenance assessment factors.
  • Maintenance reports.

Unit Five: Foundations of Maintenance Planning

  • The importance of maintenance planning.
  • Basics of designing a maintenance program.
  • Steps for implementing maintenance in the facility.
  • Preventive maintenance and its importance.
  • Advantages and disadvantages.
  • Preventive maintenance plan and practical examples.
  • Conclusion and recommendations

Unit Six: Techniques for Predictive Maintenance

  • Vibration Monitor.
  • Thermal imaging.
  • Tribology.
  • Visual inspections.
  • Ultrasounds.
  • Other techniques.

Unit Seven: The Japanese Continuous Improvement Methodology “KAIZEN”:

  • The concept of continuous improvement methodology.
  • Types of improvement methods.
  • The concept of kaizen methodology.
  • Kaizen methodology and its various roles.

Unit Eight: Benefits of Applying the Kaizen Methodology:

  • The basic components of the methodology.
  • Types of loss according to the methodology {Muda, Mura, MURI}.
  • Seven Waste in Kaizen Method {7 WASTES}.
  • Questions and surveys.

Unit Nine: The Comprehensive Method for Applying the Kaizen Methodology:

  • How do we apply the Kaizen methodology?
  • The concept of targeted processes for improvement.
  • Types of operations targeted for improvement.
  • Define improvement priorities.
  • Form improvement teams and define roles.
  • Apply improvements.
  • Work environment organization concepts.
  • The five pillars of organizing the work environment {5S}.
  • Questions, exercises and applications

The duration of the training course is 5 days, 20 training hours

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