Lean Maintenance for Military MROs

(Aircraft, Engines, Tanks, Guns & Ships)

27 - 31 May 2013, Singapore

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About Your Trainer

Mr. Fahim Ahmed : 30 years of experience in Aviation Quality Management Systems, aviation MRO and aircraft manufacturing. Fahim has worked as Deputy Chief Project Director aircraft manufacturing and Chief Engineer Joint Working Group at Center for Aircraft Design Institute China. He received his Aeronautical Engineering degree from NED and did his Masters in Engineering Management from Air University Pakistan. Fahim Is Lead Auditor QMS ISO 9000 series and implemented the system at an overhaul and manufacturing setup in Pakistan Aeronautical complex followed by transformation to AS9100 standard. Fahim has received his NDT & DMIS training from P&W USA and remained associated as Deputy Chief Engineer QMS with P&W 220E engine up gradation program for four years .In addition he has served as Chief engineer Programmed Depot Maintenance C-130 aircraft as well. His successful project collaboration in aviation spans over following international organizations. P&W USA SNECMA France CATIC China IAR SA BRASOV Romania IAE Indonesia Gulf Stream Savannah Lock Heed Martin USA

He is currently CEO of Warping Wing Aero, providing assistance in aviation systems, manufacturing audits, QMS certification, training and high tech security management services.

TEL: +65 8253 1407 FAX: +65 6271 9029 EMAIL: AMUTHA@TUN.SG ONLINE: WWW.TUN.SG

Lean Maintenance for Military MROs

27 - 31 May 2013, Singapore
Changing scenario, ever increasing sustenance of engineering systems, depletion of human resource, escalating monetary constraints, and adoption of innovative technologies, are the factors, governing the needs for an aggressive lean transformation and sustainment in MRO. In order to effectively attain these objectives, a need for MRO process improvement and transformation, coherent with internationally proven Lean practices and strategies, is considered essential. These improvements and transformations form the core of lean implementation in cellular manufacturing, systems engineering, and maintenance / supply-chain management.

Course Overview
Subject course has been premised to facilitate the understanding in Lean transformations, evolving MROs, that covers the following domains:The lean concept and its implementation strategies. The importance of Lean in MRO and Lean Maintenance integration with other improvement initiatives such as RCM, TPM, and WCM. Pre requisites to cost-effective, integrated Lean environment design and implementation, at MRO. Composition of responsive organizational structures, supplementing Lean practices. Effectiveness of Lean process in eliminating waste, improving quality, creating flow, and enhancing responsiveness to customer needs in the MRO environment.

Effective sustainment of Lean through requisite maintainability, reliability, supportability, logistics practices and technologies. Principles of maintenance and systems Engineering that are required for embedded Lean in MRO.

Who Should Attend

Subject course is devised to facilitate all levels of administrative, engineering and supply chain management, specifically those involved in implementing lean concepts in MRO organizations. The participants will gain insight on concept, application and sustainment of Lean implementation in the MRO world.

TEL: +65 8253 1407 FAX: +65 6271 9029 EMAIL: AMUTHA@TUN.SG ONLINE: WWW.TUN.SG

Lean Maintenance for Military MROs

27 - 31 May 2013, Singapore
1. Lean maintenance is a proactive maintenance concept utilizing planned and scheduled maintenance activities supplemented by Total Productive Maintenance (TPM) practices ,effectively harmonizing maintenance strategy developed through application of Reliability Centered Maintenance (RCM) and accomplished by skilled and dedicated teams employing the 5S process, Kaizen , and self directed maintenance coupled with committed and highly skilled technician utilizing work order systems automation controlled by top of the line management softwares . These Lean directions are duly supported by a comprehensive logistic network that facilitates parts and materials provisioning on a just-in-time (JIT) basis, substantiated by a maintenance and reliability engineering setup that performs root cause failure analysis (RCFA), underlying causes of parts failures, procedure and processes audits , predictive maintenance (PdM) analysis, and analysis of condition monitoring outcomes . 2. The Lean core elements, in particular TPM, should effectively be in place before an organization transforms its maintenance management pyramid, well before sustaining a continuous improvement. 3. Economic down ward trends coupled with recent recession have forced engineering MROs to review strategy in global market. Reductions in MRO activity have transformed operating costs even higher. The significant decrease in business have forced Engineering based industry to cut capacity and optimize production cost and at the same time ensure higher reliability and confidence of the customers .Similar effects are visible in the defense sector as well where an increased military operational tempo, aging weapon systems, an aging workforce, marred by curtailment of finance , and emergent new technologies have forced defense sector to institute an aggressive MRO sustainment plan that keep the aging system operating and technologically advance through the entire life cycle. The quantum leap in sustainment and efficiency can only be achieved by transforming military depot workload and processes comparable with world class commercial-type facility. 4. In order to achieve the desired transformation, Defense associated MROs require an integrated set of activities and support methods that execute their strategic vision, program concepts, acquisition , schedule, communications plan, and implementation strategy. To accomplish this objective of commercial/defense cohesion, Subject course describes in detail lean enterprise architecture (LEA) strategy to transform the MRO enterprise, encompassing the complete application of systems architecting methods to integrate, and implement a lean maintenance engineering practices in vogue. 5. This advance level course / program will help to understand methodologies that optimize and streamline the engineering base industry processes from setup to operations in extended life span , Institute cost reduction , develop quality standards and reliability to remain competitive in the industry through use of Lean maintenance methodologies . 6. Attendees of this course will walk away with viable strategies and proven Lean processes to: Understand and Utilize Lean maintenance concept to manage Engineering processes variability from setup to evaluation and infuse higher reliability in operation and Maintenance phases at commercial /defense organizations. Customize Lean Enterprise Architecture (LEA) accordingly to directly meet their business challenges in commercial as well as defense environment. Transform organizational culture for productive value streams. Deploy Change Management for effective transformation to Lean enterprise. Define and sustain LEA for vital business transformations. Apply Continuous Reliability Improvement with todays most practical LEAN practices for maintenance in commercial and defense setup. 7. Lean Maintenance for integrated commercial/Defense MROs is a 5-day professional development course for maintenance leaders, planners, coordinators and schedulers. It is specifically designed for Maintenance management at all levels, needing in-depth training for this important maintenance best practice area. This workshop is tailored for Engineering MROs, field maintenance facilities, as well as fleet management enterprise of defense and commercial sector. Its also intended to enlighten the vision of the top management trying to maximize the value of mission-essential maintenance in all tiers. 8. Representative organizations would attain true workshop oriented results through application of Continuous Reliability Improvement , supplemented by most practical Lean practices in vogue . Improved knowledge and enhanced vision of the attendees would facilitate seamless application of continuous improvement in respective organizations. They will have greater understanding of Lean applications to exercise best practices for maintenance improvement within their organizations.

TEL: +65 8253 1407 FAX: +65 6271 9029 EMAIL: AMUTHA@TUN.SG ONLINE: WWW.TUN.SG

Lean Maintenance for Military MROs

Course Outline
Day 1 Introduction to workshop objectives Introduction to Lean Origin of lean Tools and concepts of lean Using lean tools Benefits of lean in Management Maintenance Operations Logistics Lean Organization structure Lean Enterprise Architecture Methodology for Transformation Phases of LEA in MRO Importance of enterprise wide architecture Commercial and Military Applications of LEA Lean Goals Voice of customer Identifying the value stream Implementing the Pull Systems Improving the process flow Attaining lean perfection Six sigma Theory of Constraints Comparison of lean with Six Sigma and the Theory of Constraints 5S Visual Controls Cell Design / Flow Pull Systems Quick Change Total Productive Maintenance Mistake Proofing Day 3 Maintenance Best Practices Needed for LEAN The Scoreboard for Maintenance Excellence The CMMS Benchmarking System The Maintenance Excellence Index The ACT Team Process Determining PM frequencies and how to schedule PM Defining True Maintenance Requirements to Management Reliability Centered Maintenance Disadvantage of unreliability Cost of Maintenance Reactive and Proactive Maintenance Total Productive Maintenance Maintenance Performance Management Performance and Business Alignment Performance Indicators for maintenance Interpretation for Corrective Action CMMS contribution Classification of workloads ,materials Managing asset Detection of faults & failures Going LEAN for Maintenance Excellence is Improving Key Maintenance Practices Day 4 Preventive Maintenance Predictive Maintenance Chemical Predictions Mechanical predictions System safety Failure Reporting and Corrective Action System (FRACAS) Planning and Scheduling Logistics Control Energy Management Security and Access Control Skills Development CMMS: The Maintenance Business System Day 5 Continuous Reliability Improvement Lean Application to Maintenance Techniques How Lean Improves the Planning Process and Scheduling Process How technology supports the lean process Materials Management and Purchasing Support to Proactive, Planned Lean Maintenance Lean Practices for Successful Scheduling & Backlog Management Measuring Bottom-Line Results for Lean Investments Measuring the Performance of the Overall Maintenance Operations Selecting Key Performance Metrics Developing a Maintenance Excellence Index Dealing with Probability and Risk Tips and Tricks to avoid Pitfalls Introduction to the Earned Value Analysis Technique Conclusion and final review

Day 2 Lean Production & Lean Maintenance Flow and Value 12 Forms of Waste 10 Principles for Lean Change 10 Tools for Achieving Lean Typical Lean Steps & Spaghetti Chart Cell Layout Configured for Product Flow Batch Production vs. Lean Productions Comparative analysis of Lean & Batch Flow Simulation & Hands-On Exercise Applying Lean to the Maintenance/MRP Storeroom Managing Life-Cycle Information of Aircraft Components Radio-Frequency Identification (RFID) Item-Unique Identification (IUID) Scheduled Removal Component (SRC) Planning and Scheduling as a Key Lean performer to Improve Productivity Organizing and Managing LEAN Practices Leadership roles of LEAN in Maintenance: Key Roles Tools for LEAN Improvement Key Principles of Waste Elimination Identifying Value Current State Analysis Tools Product Quality Analysis Task Time: Customer Demand Process Mapping Spaghetti Charts Current State Analysis Tools Forms of Waste Principles for Lean Change Tools for Achieving Lean

TEL: +65 8253 1407 FAX: +65 6271 9029 EMAIL: AMUTHA@TUN.SG ONLINE: WWW.TUN.SG

Lean Maintenance for Military MROs

27 - 31 May 2013, Singapore
Redhill Forum, 16 Jalan Kilang Timor #03-07, Singapore 159308 Fax: +65 6271 9029

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T.U.N INTERNATIONAL reserves the right to replace or modify the advertised speakers/topics should there be circumstances beyond the control of the organizers before the event. Any changes will be updated on our website as soon as possible.

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Lean Maintenance for Military MROs 27 - 31 May 2013, Singapore

SGD 5,499
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Above fees exclude any withholding taxes Above fee includes refreshments, lunches & course materials If you do not receive a confirmation from us within 1 business day of sending in your form, kindly contact us to reconfirm your seat. Any late payment will be subjected to a 5% late payment fee if the full payment is not received before the commencement date of the course.

If you are unable to attend the training course for which you have registered, you may send a substitute free of charge. If you cannot send a substitute or otherwise need to cancel your class registration, please provide written notice to us via e-mail at admin@tun.sg. Cancellation requests received by T.U.N INTERNATIONAL seven (7) days or more prior to the course start date will receive full credit for use in another future course with no time limit. Credit is not available for cancellation requests received by T.U.N INTERNATIONAL seven (7) or fewer days before the course start date. T.U.N INTERNATIONAL reserves the right to alter or change any part of the course. In the event T.U.N INTERNATIONAL cancel a course due to inclement weather, or other events beyond our control, the fees will be credited to a future seminar of the registrants choice. Upon registration, the registrant acknowledges that T.U.N INTERNATIONAL will not be held liable for any charges or fees incurred due to the cancellation of travel or accommodation reservations. T.U.N INTERNATIONAL - BIZ REGISTRATION NO 53128089J

TEL: +65 8253 1407 FAX: +65 6271 9029 EMAIL: AMUTHA@TUN.SG ONLINE: WWW.TUN.SG