COURSE OVERVIEW:

In a modern industrial environment, it is neither practical nor cost-effective to maintain all assets with the same level of intensity. This course provides a strategic framework for Criticality Analysis, a process that ranks mechanical equipment based on its impact on safety, environment, production, and maintenance costs. Participants will learn how to move away from "one-size-fits-all" maintenance and instead develop a prioritized approach that allocates resources where they provide the highest value to the organization.

The scope of the training encompasses the various methodologies used to determine asset criticality, including qualitative, semi-quantitative, and quantitative risk assessments. We will examine how to build a robust criticality matrix and how to define the specific criteria that drive equipment ranking. This process forms the foundation for selecting the most appropriate maintenance strategy—whether it be Preventive (PM), Predictive (PdM), Proactive, or Run-to-Failure (RTF)—ensuring that maintenance efforts are perfectly aligned with business objectives.

Furthermore, the course bridges the gap between theoretical risk assessment and practical execution. Attendees will learn how to use criticality rankings to optimize spare parts inventory, prioritize work orders, and refine Reliability Centered Maintenance (RCM) programs. By the end of the course, participants will be able to lead a multidisciplinary criticality team, facilitating data-driven decisions that enhance plant reliability while simultaneously reducing unnecessary maintenance expenditures.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Define the fundamental principles of Asset Criticality Analysis (ACA).
2. Facilitate a multidisciplinary team to perform equipment criticality ranking.
3. Develop clear criteria for evaluating safety, environmental, and production risks.
4. Construct a customized 5x5 or 3x3 Criticality Matrix for their facility.
5. Distinguish between different maintenance strategies: PM, PdM, and RTF.
6. Align maintenance tasks with the specific failure modes of critical assets.
7. Use criticality data to prioritize maintenance backlogs and work schedules.
8. Optimize spare parts stocking levels based on equipment criticality scores.
9. Justify the investment in advanced predictive technologies for "A" class assets.
10. Integrate criticality analysis results into the CMMS (Computerized Maintenance Management System).
11. Perform a "Review of Existing Maintenance" (REM) based on new criticality data.
12. Calculate the "Risk Priority Number" (RPN) for mechanical systems.
13. Establish a continuous improvement loop to update criticality as plant conditions change.

TARGET AUDIENCE:

Maintenance Managers, Reliability Engineers, Asset Management Professionals, Operations Supervisors, and CMMS Administrators are responsible for maintenance planning and strategy.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.