SYNOPSIS

Workers and management in many companies complain that they are too busy to take care of equipment or to perform routine maintenance activities. They run the equipment until it breaks and then complain that they are behind in their work because the equipment is unreliable. Breakdowns create havoc in low-inventory factories. They also lower quality, cause increases in inventory, ruin morale, cost money, delay schedules and waste resources. Preserving and maintaining the reliability of equipment is an essential task in a successful factory.

An effective program usually include in-depth study of preventive maintenance techniques, followed by a thorough program of maintenance control in which vital equipment is repaired before it breaks down. It is better to fix problems when they are small and seemingly insignificant than to wait for the problem to rise to “broken” proportions. This course will provide an insight of maintenance management systems and how to integrate daily operations together with maintenance. This way the company not just benefit from minimum breakdown but also from higher productivity.

This course will cover topics on maintenance policies which include breakdown maintenance, design out maintenance, preventive maintenance, condition monitoring and failure patterns. Engineering asset maintenance discuss topics on maintaining engineering assets (machine and equipment), preventive maintenance as well as autonomous maintenance. Zero breakdown covers approaches towards zero breakdown, supplier appraisal and strategy for new and existing assets. Maintenance cost is important to keep the cost low and can be managed through proper manpower, spare parts, overhead and contractors planning. Maintenance outsourcing is commonly practiced and it is important to determining the right cost, proper contractor selection and control of contractors performance.

Statistical methods for maintenance improvement can be used for variation and diagnosis through structured data collection and analysis with the use of check sheet, Pareto diagram and cause and effect analysis. Occupational safety and health hazards in in maintenance can be achieved through safe maintenance procedures and maintenance control. Design for maintainability includes analysis of design failure and issue on reliability and maintenance frequency.


COURSE OBJECTIVE

On completion of the course, participants shall be able to:

1.  Define and identify the features of maintenance management system
2.  Define and identify the steps to successfully implement preventive maintenance, maintenance
     prevention and equipment management
3.  Identify the steps to implement TPM company-wide maintenance management system
4.  Identify losses and failures associated with equipments and the manufacturing process
5.  Identify steps to eliminate losses and failures


BIODATA OF SPEAKER

Dr. Abdul Rahman Abdul Rahim is an Associate Professor at UTM Razak School of Engineering and Advanced Technology, UTM Kuala Lumpur. He is also an associate lecturer at Meiji University, Tokyo, Japan. Prior to joining UTM he has worked with two multi-national corporations in the area of manufacturing. He graduated with a B.Sc. in Mechanical Engineering and B.Sc. in Engineering Management from University of Evansville USA in 1988. He obtained his MSc in Manufacturing Systems Engineering from Warwick University in 1991 and his PhD from Universiti Teknologi Malaysia in 2006. He also received a Certificate in Occupational Safety and Health in Manufacturing Industries from Worksafe Western Australia in 1998. At present, he is the coordinator of Safety and Health Officer Course organized by Federation on Malaysia Manufacturers (FMM).

He has conducted training with various multi-national and local companies throughout Malaysia in the area of Operations and Production Management, Occupational Safety and Health, Emergency Response Plan, 5-S and Housekeeping, Project Management, Total Productive Maintenance, Poka Yoke, Quality Improvement, Statistical Process Control, ISO 14000, ISO 9000, HACCP, GMP, Production Planning and Control and Method and Time Study. He is also an invited speaker at Federation of Malaysian Manufacturers (FMM), National Institute of Occupational Safety and Health (NIOSH), Malaysian Institute of Human Resource Management (MIHRM), Incorporated Society of Planters, (ISP), ALAM, International Business School (IBS), Chemical Engineering Pilot Plant (CEPP), and Business and Advanced Technology Center (BATC), Institut Pembangunan Pengurusan Johor (IPPJ), Prestariang and Pusat Pembangunan Tenaga Industri Johor (Puspatri). He has also conducted training for Sudan Master Technology (SMT) in Khartoum in 2014. He was also an examiner and interviewer for Safety and Health Officer competency certificate (NIOSH).