PREDICTIVE AND PREVENTIVE

MAINTENANCE
18 & 19 JANUARY 2023
ROYALE CHULAN DAMANSARA
TRAINING PROGRAMME NO.: 1000119452

Our Consultant: Mr. S. Nyana Pragasam

Where traditional maintenance management programs rely on routine servicing of all machinery and fast
response to unexpected failures, a predictive maintenance program schedules specific maintenance
tasks as they are actually preventing and extending equipment life usefulness.

To understand a predictive maintenance management program, traditional management techniques

should first be considered in order to understand machine failures

When a machine breaks down, fix it. The “If it ain’t broke, don’t fix it” method of maintaining plant
machinery has been a major part of plant maintenance operations.
 PREDICTIVE AND PREVENTIVE MAINTENANCE

TRAIN INSANE,
OR REMAIN THE SAME.
 PREDICTIVE AND PREVENTIVE MAINTENANCE

COURSE OVERVIEW

Where traditional maintenance management programs rely on routine servicing of all machinery and fast
response to unexpected failures, a predictive maintenance program schedules specific maintenance tasks
as they are actually preventing and extending equipment life usefulness.

To understand a predictive maintenance management program, traditional management techniques

should first be considered in order to understand machine failures

When a machine breaks down, fix it. The “If it ain’t broke, don’t fix it” method of maintaining plant machinery
has been a major part of plant maintenance operations.

COURSE OBJECTIVES

• To provide the insight of why equipment breakdown

• To understand the real objective of maintenance
• Define why equipment deteriorate
• How to use the time base schedule maintenance
• How to use the condition base predictive maintenance
• Strategize for zero unplanned equipment failures.

COURSE BENEFITS

• Participant will be exposed how to approach the zero-breakdown strategy

• Gained proper strategy to achieve zero failure
• Increase the productive, reduce the breakdown

WHO SHOULD ATTEND

Quality Assurance, Quality Control, Production, Process, Managers, Executives, Engineers, Supervisors,
Technicians and anyone who would like to improve their knowledge in Maintenance.

Also, for those who are in operations would like to acquire an understanding of how the quality of the
maintenance activities affects their equipment functions if wrong type of elements used.
 PREDICTIVE AND PREVENTIVE MAINTENANCE

COURSE CONTENT

Module 1: Objectives of Equipment Maintenance

• Maintenance Overview
• The objectives of equipment maintenance
• What Planned Maintenance wants to achieve.
• The changing world of maintenance

Module 2: Types of Maintenance Strategies

• Preventive Maintenance
• Predictive Maintenance
• Break down Maintenance
• Total Productive Maintenance (7 Steps)
• Reliability Centered Maintenance (7 Questions)
• Other Combination Maintenance

Module 3: Maintain Basic Equipment Condition

• Why maintain basic condition.

• The TPM approach 7 steps Autonomous maintenance.
• The role of operators in basic maintenance.
• Basic TLIC system

Module 4: Systematic Preventive Maintenance

• Explain Physics of Failure and why machines fail.

• 6 losses of equipment deterioration
• 6 life cycle curves of equipment deterioration.
• Why preventive maintenance.
• What happens when schedule maintenance not done.

Module 5: Step by Step Implementing Schedule Maintenance

• Analyzing the equipment data using Pareto analysis (QC tool)

• Assigning the type of preventive maintenance Task.
• Developing preventive maintenance checklist.
• Developing preventive maintenance schedule.
• Developing the pm expertise
- Systematic execution.
- Monitoring the effectiveness
 PREDICTIVE AND PREVENTIVE MAINTENANCE

Module 6: Predictive Maintenance

• Definition of predictive maintenance.

• Objectives of predictive maintenance.
• Myths about predictive maintenance.
• Why on-condition- monitoring.
• How to determine p-f curve
• What is P-F interval
• Benefits of predictive Maintenance

Module 7: Predictive Maintenance Technique

Explain how to select the equipment items from which condition data will be collected

• Vibration analysis
• Tribology analysis
• Ultrasonic inspection
• Thermography analysis
 PREDICTIVE AND PREVENTIVE MAINTENANCE

TENTATIVE SCHEDULE

*Training schedule is tentative and may be subject to change.

DAY 1

Time Schedule Outline

9.00 am – 10.30 am Module 1: Objectives of Equipment Maintenance

• Maintenance Overview
• The objectives of equipment maintenance
• What Planned Maintenance wants to achieve.
• The changing world of maintenance

10.30 am – 10.45 am Tea Break

10.45 am – 1.00 pm Module 2: Types of Maintenance Strategies

• Preventive Maintenance
• Predictive Maintenance
• Break down Maintenance
• Total Productive Maintenance (7 Steps)
• Reliability Centered Maintenance (7 Questions)
• Other Combination Maintenance

1.00 pm – 2.00 pm Lunch

2.00 pm – 3.30 pm Module 3: Maintain Basic Equipment Condition

• Why maintain basic condition.

• The TPM approach 7 steps Autonomous maintenance.
• The role of operators in basic maintenance.
• Basic TLIC system

3.30 pm – 3.45 pm Tea Break

3.45 pm – 5.00 pm Module 4: Systematic Preventive Maintenance

• Explain Physics of Failure and why machines fail.

• 6 losses of equipment deterioration
• 6 life cycle curves of equipment deterioration.
• Why preventive maintenance.
• What happens when schedule maintenance not done.
 PREDICTIVE AND PREVENTIVE MAINTENANCE

DAY 2

Time Schedule Outline

9.00 am – 10.30 am Module 5: Step by Step Implementing Schedule Maintenance

• Analyzing the equipment data using Pareto analysis (QC

tool)
• Assigning the type of preventive maintenance Task.

10.30 am – 10.45 am Tea Break

10.45 am – 1.00 pm Cont’d. - Module 5: Step by Step Implementing Schedule

Maintenance

• Developing preventive maintenance checklist.

• Developing preventive maintenance schedule.
• Developing the pm expertise
- Systematic execution.
- Monitoring the effectiveness

1.00 pm – 2.00 pm Lunch

2.00 pm – 3.30 pm Module 6: Predictive Maintenance

• Definition of predictive maintenance.

• Objectives of predictive maintenance.
• Myths about predictive maintenance.
• Why on-condition- monitoring.
• How to determine p-f curve
• What is P-F interval
• Benefits of predictive Maintenance

3.30 pm – 3.45 pm Tea Break

3.45 pm – 5.00 pm Module 7: Predictive Maintenance Technique

Explain how to select the equipment items from which condition
data will be collected

• Vibration analysis
• Tribology analysis
• Ultrasonic inspection
• Thermography analysis
 PREDICTIVE AND PREVENTIVE MAINTENANCE

OUR CONSULTANT

Mr S. Nyana Pragasam holds academic qualification in Master of Science in Manufacturing, holds Bachelor
of Science Electrical and Electronic Engineering and Diploma in Mechanical Engineering. He is also a Member
of the International Association of Engineers (IAENG)

He is an accomplished practitioner, consultant and trainer in the areas of Maintenance Management System,
specialized in ISO 9001, ISO/TS 16949/ LRQA implementation, conducting internal and external audits and
certification at Factory Level. He is also a certified plant auditor for ISO/TS 16949, LRQA and TPM (PM).

Mr S. Nyana Pragasam has more than 25 over years of working experience, started his career at Siemens
Malaysia later at Motorola Semiconductor, in the areas of Quality, Productivity, Maintenance discipline and
has served in Managerial position improving Productivity, Quality, Cost and Safety.

He has participated to some of the major trainings such as ISO 9000/ TS16949 Quality Management System,
Train the Trainer, 6 Sigma Program, Failure Mode Effects Analysis (FMEA), 7 QC Tools, 7 Advance Quality
Management Tools, Total Productive Maintenance and Reliability Centered Maintenance and Cost, Productivity
and Quality Improvements programs improving Departmental Operations.

His major accomplishments were in coordinating TPM (PM) teams, in-line with Organization goal to achieve
JPIM award, coordinating and maintain maintenance culture in Total Productive Maintenance (TPM) towards
zero defects, equipment losses, 5S and cost reduction improvement programmes activities for Organizations
growth.
With his skills and knowledge, he has also extended his auditing competency and machinery set up for
Contract Manufacturing Industries improving their Operational cost and increasing their productivity for
locally and overseas.

Mr S. Nyana Pragasam has conducted numerous training programmes for technician, engineers and managers
in Total Productive Maintenance, Basic Mechanicals Maintenance, Reliability Centered Autonomous
Maintenance for MNC’s companies.

He has also been awarded for best paper presentation, technical awards for redesigns, Poka yoke, building
locally Trim equipment for high avoidance and Motorola GM award for significant capacity improvement.
 PREDICTIVE AND PREVENTIVE MAINTENANCE

18 & 19 JANUARY 2023

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