Developing a World-Class Maintenance Practice is one step towards Business Excellence. Advanced Maintenance Strategy can help you to maintain core disciplines, drive improvement, identify best practices, and develop a maintenance organization, effective failure management and program development.

1. Advanced Maintenance Strategy
B Tech from IIT Roorkee, PGDM from IIM
Calcutta and is an Ex IES officer with
intensive experience in various sector. He is
a certified Lean Six Sigma Black Belt
Trainer
He has helped manufacturing companies
turn-around by implementing
Manufacturing Excellence , Six Sigma,
TPM, TQM, Mfg Strategy and New Product
Development & Breakthrough Innovation
He is a passionate reader and have
inclination to solve complex business.
Know Your Trainer
© Tetrahedron Manufacturing Services Pvt Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Who should attend
Department Head
Quality Professional
Maintenance Professional
Project Management Professional
Plant Engineering
Innovation Manager
Management Representative
This session will help the participants to
1. Identify planning best practices and key
elements for taking action on them
2. Understand how world-class organizations solve
common planning problems
3. Evaluate your practices compared to those of
others
4. Improve the use of your information and
communication tools
5. Improve productivity through use of better,
more timely information
6. Create and preserve lead-time in work
management and use it for planning and
scheduling resources
7. Improve consistency and reliability of asset
information
8. Optimize preventive and predictive maintenance
strategies
9. Audit your maintenance operations
10.Use the results to develop and improvement
strategy
11.Establish Auditing and Performance Indicators
as a key element of the maintenance strategy
Benefits of attending
Technical Workshop Series
Developing a World-Class
Maintenance Practice is one step
towards Business Excellence.
Advanced Maintenance Strategy can
help you to maintain core disciplines,
drive improvement, identify best
practices, develop a maintenance
organisation, effective failure
management and program
development.

2. Workshop Agenda
© Tetrahedron Manufacturing Services Pvt. Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Safety in maintenance
a. Myths about safety
b. Why the concern for safety
c. Unsafe acts and unsafe conditions
d. Safety culture elements
e. Conducting safety audits
Basic Maintenance to Adv Maintenance
Condition Monitoring
a. Visual Monitoring
b. Performance Monitoring
c. Monitoring of Vibrations and Noise
d. Monitoring of Wear Debris
e. Heat Monitoring
Two Important CM Techniques: Analysis of
Vibrations and Lubricating Oil
a. Analysis of Vibrations
b. Analysis of Lubricating Oil
c. Advantages and Applications
d. The Parameters Monitored
e. The Definition of Alarm Thresholds and Oil
Sampling Methods
f. Oil Analysis Techniques
g. Monitoring of Lubricant Properties
Information Technology to Support of CM
Soft Computing Technologies for CM
Testability and Prognostics
Testability
a. Testability Figures of Merit
b. Management of Testability
Prognostics
a. Prognostics and Availability
b. Logistical Parameters Correlated to Prognostics
c. The Figures of Merit of Prognostics
d. Testability Figures of Merit Applicable to
Prognostics, Implementation of Prognostics
e. The Process of Prognostics Planning
Maintenance Auditing & Improvement
a. Introduction to Maintenance Auditing and
Benchmarking
b. The Maintenance Auditing Process
c. Maintenance Auditing Methodology
d. Conducting a Maintenance Audit
e. Interpreting Audit Results
f. Using Auditing and Benchmarking to drive
improvement
Performance Indicator & Mgmt Reporting
Managing and Measuring Progress to Excellence
Information and Control, Management Levels and
Information, Maintenance Performance Indicators
Management Reports, Continuous Improvement in
Maintenance,
Technical Workshop Series
Introduction to Advanced Maintenance
a. Maintenance in the Business Process
b. Objectives of maintenance management
c. Evolution in Maintenance Management
d. The Maintenance Management Environment
and the need for improvement
e. Maintenance life cycle
f. Common maintenance management problems
g. Typical responsibilities of a maintenance
manager
h. The maintenance organization
i. Structure and content of Maintenance
Management Strategy
Maintenance Policies and Strategies
Introduction
Reliability-Centred Maintenance
The Principles and Phases of RCM
Total Productive Maintenance
Maintenance Strategies
a. Breakdown Maintenance
b. Preventive Maintenance
c. Predictive Maintenance
d. Proactive Maintenance
The Choice of the Most Opportune Strategy
The Maintenance System
a. Maintenance Management
b. Programming of Maintenance
c. Performance of Maintenance
d. Maintenance Engineering
The Movement of Maintenance Management
Towards the Services Economy
a. Subcontracting
b. The Establishment of External Companies
c. Outsourcing
Facility Management
The Global Service of Maintenance
Maintenance planning and control
a. Maintenance work flow process
b. Work requests and work orders
c. Work planning and scheduling
d. Backlog management
e. Resource management
f. Spare parts management
g. Maintenance master budget
h. Capital budgeting
i. Maintenance initiatives
j. Replacement analysis of assets
k. Maintenance operating budget
l. Innovation and creativity

3. Reliability Centered Maintenance ( RCM)
B Tech from IIT Roorkee, PGDM from IIM
Calcutta and is an Ex IES officer with
intensive experience in various sector. He is
a certified Lean Six Sigma Black Belt
Trainer
He has helped manufacturing companies
turn-around by implementing
Manufacturing Excellence , Six Sigma,
TPM, TQM, Mfg Strategy and New Product
Development & Breakthrough Innovation
He is a passionate reader and have
inclination to solve complex business.
Know Your Trainer
© Tetrahedron Manufacturing Services Pvt Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Who should attend
Department Head
Quality Professional
Maintenance Professional
Project Management Professional
Plant Engineering
Innovation Manager
Management Representative
This session will help the participants to
1. Understand the effect of maintenance activity
in overall performance of organization
2. Conduct the failure analysis and train other on
the same
3. Conduct FMEA with maintenance perspective
4. Conduct COFA and develop logic tree
5. Prepare for RCM implementation
6. Determine design change required and
communicate the same
7. Develop Preventive Maintenance (PM)
worksheet and execute it
8. Conduct maintenance of Devices and
instruments
9. Measure and Monitor RCM performance
The delivery method will be combination of
theory, examples, case study, group work and
individual exercise during the session. Also based
on the session progress and intensity there will be
some fun learning elements to break monotony.
The faculty will facilitate the workshop by visually
appealing power-point and videos where ever
required
Benefits of attending
Technical Workshop Series
Companies overall profit is driven
directly by the up-time of all
equipments, devices and instrument.
RCM helps company to reduce the
downtime and unavailability to
maximum extent and help people to
conduct reviews of overall health of
all equipment and make plan for
corrective action in case required.

4. Workshop Agenda
© Tetrahedron Manufacturing Services Pvt. Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Session 1 Introduction to RCM
The Changing world of Maintenance
I. Maintenance and RCM
II. A No-Nonsense Approach to RCM
III. RCM as a Major Factor in the Bottom Line
Session 2 Fundamental RCM Concepts
I. Understand the Three Phases of an RCM-Based
Preventive Maintenance Program
II. Know what are the Three Cornerstones of RCM-Single-
failure analysis, Hidden-failure analysis, Multiple-
failure analysis
III. Understand the Missing Link: Potentially Critical
Components, Commitment Components, Economic
Components
IV.What is “Canon Law “of Run-to-Failure Components
V. Integrate of Preventive and Corrective Maintenance
VI.What is the Anatomy of a Disaster
VII.How to Find the Anomalies,
VIII.Understand Component Classification Hierarchy
Understand different RCM analysis Processes:
FMEA,FMECA and COFA
Session 3: RCM Implementation: Preparation
Preparation needed before RCM implementation
i. Comprehensive Equipment I.D.Database
ii. Informational Resources
iii. Establishing Convention
iv. The COFA Excel Spreadsheet versus the FMEA
v. The PM Task Worksheet
vi. The Economic Evaluation Worksheet
Session 4 : Implementation Process-Phase 1
Implement RCM through COFA Worksheet with the
COFA Logic Tree, the Potentially Critical Guideline,
and the Economically Significant Guideline
i. Describe the Component Functions
ii. Describe the Functional Failures
iii. Describe the Dominant Component Failure Modes for
Each Functional Failure
iv. Is the Occurrence of the Failure Mode Evident?
v. Describe the System Effect for Each Failure Mode
vi. Describe the Consequence of Failure Based on the
Asset Reliability Criteria You Selected
vii.Define the Component Classification
How to implement RCM through FMEA/FMECA
i. Determine System Boundaries
ii. Determine Subsystem Boundaries
iii. Determine Interfaces , Determine Functions
iv. Determine the Functional Failures
v. Determine Equipment Responsible for Failures
Case Study: Averting a Potentially Devastating Plant
Consequence
Session 5: Implementation Process-Phase 2
How to do PM Task Selection Process
i. Understanding Preventive Maintenance Task
Terminology
ii. Condition-Directed, Time-Directed, and Failure-Finding
Tasks
iii. The PM Task Worksheet
iv. The PM Task Selection Logic Tree
v. Why a Condition-Directed Task Is Preferred
vi. Determining the PM Task Frequency and Interval
vii. Is a Design Change Recommended?
viii.Completing a Typical PM Task Worksheet
ix. Institute Technical Restraints
x. A Sampling Strategy
xi. Common Mode Failures
xii. Different Predictive Maintenance (PdM) Techniques
Vibration Monitoring and Analysis , Acoustic
Monitoring, Thermography or Infrared Monitoring
Oil Sampling and Analysis, X-ray or Radiography
Inspection, Magnetic Particle Inspection
Session 6: RCM for Instruments-Phase 3
Instrument Categories
Instrument Design Tolerance Criteria
The Instrument Logic Tree
i. Instrument Is Analyzed in the COFA Worksheet and
the PM Task Selection Worksheet.
ii. A PM Is Required. Calibration Criteria and Periodicity
Guidance Are as Follows.
iii. Were the Last Three Successive Calibrations Within
Vendor Tolerance Criteria?
iv. Periodicity Extension Is Allowed.
v. Reduce Periodicity or Implement a Design Change.
vi. Is an Indication Comparison Applicable?
vii. Is the Consequence of Excessive Drift Acceptable?
viii. Were the Last Two Successive Calibrations Within a
+/−2.5 Percent Accuracy Tolerance?
ix. Periodicity Extension Is Allowed.
x. Were the Last Two Successive Calibrations Within a
+/−5.0 Percent Accuracy Tolerance?
xi. Periodicity Extension Is Not Allowed.
xii. Reduce Periodicity or Implement a Design Change.
Session 7 :Monitoring & Trending - Phase 4
Measuring Reliability & Aggregate Metrics
Unplanned Plant or Facility Trips, Capacity Factor,
Unplanned Operator Actions, Unplanned Power
Reductions, Production Delays, Enforcement Actions,
Litigation Occurrences, Citations and Violations, Root-
Cause Evaluations, Injuries, Rate of Written CMs, Overdue
CM Backlog, Overdue PM Backlog, Weighting
Factors,Performance Calculations and Performance Graph
by System, Avoid Reliability Complacency, How to
Maintain Your Reliability Performance
Technical Workshop Series

5. Modern Maintenance & Reliability Management:
Planning and Estimating
B Tech from IIT Roorkee, PGDM from IIM
Calcutta and is an Ex IES officer with
intensive experience in various sector. He is
a certified Lean Six Sigma Black Belt
Trainer
He has helped manufacturing companies
turn-around by implementing
Manufacturing Excellence , Six Sigma,
TPM, TQM, Mfg Strategy and New Product
Development & Breakthrough Innovation
He is a passionate reader and have
inclination to solve complex business.
Know Your Trainer
© Tetrahedron Manufacturing Services Pvt Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Who should attend
Department Head
Quality Professional
Maintenance Professional
Project Management Professional
Plant Engineering
Innovation Manager
Management Representative
This session will help the participants to
1. Demonstrate the bottom -line benefits of
Maintenance Planning and Scheduling as a core
business process
2. Perform the critical steps in the identification of
necessary maintenance work
3. Develop a proactive maintenance planning system
to reduce costs, downtime and backlogs
4. Achieve streamlined maintenance processes by
developing a fool-proof scheduling program
5. Analyze work requests using a risk-based approach
so only necessary work is performed
6. Apply proven performance measurement tools
tailored to your maintenance conditions in order to
guarantee the successful execution of maintenance
work
7. Develop an accurate and reliable maintenance
history through tracing and analyzing maintenance
8. Improve turnaround performance by applying
proven best practices
9. Utilize best practice performance management in
order to control your Maintenance Planning
10.Effectively decrease downtime by coordinating and
streamlining your Maintenance Planning,
Scheduling and Control Process
Benefits of attending
Technical Workshop Series
Maintenance Planning and Scheduling
is one of the most important
elements in modern maintenance
management. Maintenance Planning
and Scheduling is also synonymous
with control of maintenance. In order
for maintenance planning and
scheduling to work many other
systems need to work well. Most
importantly equipment inspections
through preventive maintenance.

6. Workshop Agenda
© Tetrahedron Manufacturing Services Pvt. Ltd
Phone : +91 7042140046 Email : training@tetrahedron.in
Tetrahedron Academy
Routine Restoration and Discard Tasks
Routine Condition-Based Tasks
Failure-Finding Tasks
The Application of RCM in the Development of
Failure Management Policies
Implementing Failure Management Policies
5-Work Planning, Scheduling and Control
Planning and Controlling Maintenance Materials
a. Accurate Inventory Status and Effective Parts
Procurement Lowers M TTB (Mean Time to Repair)
and Total Costs
b. Considerations in Inventory Decisions
c. Economic Order Quantity (EOQ)
d. Total Material Cost
e. Definition of Notifications, Defects, Deviations
f. Notification Process, Roles and Principles
g. Weekly Master Schedule
i. Define Total Maintenance Requirements
(Backlog) to Top Leaders
ii. Master Schedule Objectives
iii. Categorizing the Outstanding Workload
iv. Determine Resource Availability
v. Determine Equipment Non-Utilization Profile
vi. Develop Draft Master Schedule
vii.Conduct Master Schedule Review Meeting
viii.Final Master Schedule and Implementation
ix. Backlog Management
6-Controlling Maintenance Work
Measuring Performance, Sources of Data
Backlog Indices, Schedule Compliance
PM and Emergency Indices, Productivity
Indicators
7-Information & Performance Management
Planning and Scheduling of Major Maintenance WOs
and Shutdowns
Planning and Scheduling, Work Breakdown
Structure, Critical Path Method (CPM), Resource
Scheduling and Leveling, Safety in Maintenance
Safety Audit
8-Life Cycle Cost of Equipment
a. Capital Budgeting, Accounting Rate of Return
(ARR), Payback Method
b. Net Present Value Method (NPV)
c. Replacement Analysis of Equipment
d. Performance Indicators
e. Workload Performance Indicators
f. Planning Performance Indicators
g. Effectiveness of Performance Indicators
h. Cost of Performance Indicators
Management Reports
Technical Workshop Series
1-Modern Maintenance Management
Practices as a Business Strategy
a. Maintenance in the Business Process
b. Objectives of maintenance management
c. Evolution in Maintenance Management
d. The Maintenance Management Environment and the
need for improvement
e. Maintenance life cycle
f. Common maintenance management problems
g. Typical responsibilities of a maintenance manager
h. The maintenance organization
i. Structure and content of Maintenance Management
Strategy
2-Maintenance Policies &Logistics Planning
a. Equipment Classification and Identification
b. Maintenance Management Policies
c. Equipment Criticality Grading
d. Job Record Policy
e. Principles of Work Order Design
f. Maintenance Work Prioritization
g. Logistic Support Analysis
h. Maintenance Work Estimating
i. Maintenance Levels
j. Support Documentation
k. Support Equipment
l. Maintenance Logistics Planning
3-Predictive and Condition-Based
Maintenance (PM-PdM-CBM)
a. Understanding PM-PdM-CBM Areas of Application
b. Integrating Risk Based Maintenance (RBM) into Work
on Critical Assets
c. Implementing a PM-PdM-CBM Program
d. Establishing Effective Scheduling Process
e. Breaking a Facility Into Logical Parts and Level
Loading of PM-PdM-CBM
f. Developing an Equipment List and using Modern
Identification Techniques
g. Writing PM Task Lists and Having Continuous
Updating/Review
h. Documenting and Validating Results of PM-PdM-CBM
4-Review of RCM for Planner/Schedulers
Failure Modes, Effects and Consequences
Equipment Functions and Performance
Standards
Functional Failures
Failure Modes & Failure Effects
Consequences of Failure
Failure Management Policies
Age Related Failure Patterns
Random Failure Patterns