Maintenance Certification Program
Success in the cement industry depends on constant differentiation, evolution, innovation, and an ongoing drive to improve efficiency.
Maintenance Management
Describe the roles and goals of a maintenance manager/supervisor. List maintenance management critical success factors. Practice techniques to effectively manage people's performance. Implement KPIs that drive desired results. Apply budgeting tools and processes.
Maintenance Planning and Scheduling
Define the planner/scheduler environment. Differentiate between reactive, preventive, and predictive maintenance. Develop an effective planning program. Manage scheduling and coordination. Create compelling job plans.
Materials Management
Identify effective materials management processes. Implement effective inventory control and warehouse best practices. Describe how a CMMS supports materials management. Identify contributors to the total cost of materials. Define the standard set of materials management key performance indicators.
Predictive Maintenance Application
Explain how predictive maintenance mitigates risk. Describe PdM theory, application, and safety factors. Recognize visual inspection as a component of PdM. Draft a predictive maintenance strategy. Compare your current PdM program to best practices.
Root Cause Analysis
Outline a 6-step root cause analysis process. Outline triggers for RCA efforts. Select and apply a range of RCA tools to solve different problems.
Risk-Based Asset Management
Draft an asset management plan. Describe asset management information required to manage risk. List ways to extend the life of assets and evaluate their effectiveness. Use FMEA to analyze risks and map control strategies. List critical internal and external asset management partners.
Complete the Maintenance Certification Program in five weeks
This program combined theory and hands-on application for the cement industry with the six-key components needed to become a maintenance specialist or future maintenance managers, professionals responsible for building and sustaining a world-class maintenance program.
Architectural thinking
You will learn practical skills that can be applied immediately to the job role, improving productivity, maintenance quality, and overall manufacturing and production plants’ overall effectiveness.
Training Program Objective
Help the maintenance staff improve productivity and the workforce’s quality, anticipate and eliminate possible delays, quantify the risk, and prevent its impact through the planning, scheduling, and coordination of maintenance resources, parts, materials, and access to equipment.
This certification program will enable you to:
- Build and sustain a maintenance program.
- Establish appropriate maintenance KPI’s and visual management dashboard.
- Select the optimum equipment maintenance strategy.
- Meet your production goals and maintain your valuable assets.
- Implement work management strategies that improve asset availability and utilization.
- Increase maintenance personnel productivity.
- Build a problem-solving culture.
- Manage an adequate maintenance budget.
Organizational benefits
The Maintenance certification program will cover the following topics during the five weeks of the course.
Week 01
Maintenance Certification Program
- An introduction to the cement industry
- An introduction to Portland cement manufacture
- Process control in the cement industry
- Cement chemistry and quality control
- Environment and dust collection
- Cement plant safety
- Raw materials extraction/quarry operations
- Material handling and transportation
- Management of the maintenance department (KPI’s)
Week 02
Maintenance Certification Program
- Management of the maintenance department
- Basic metallurgy, wear, and temperature resistant materials
- Welding procedures and applications
- Lubrication and tribology
Week 03
Maintenance Certification Program
- Electricity in the cement industry
- Gear design and applications
- Pneumatics and compressed air
- Hydraulics in the cement industry
Week 04
Maintenance Certification Program
- Fan design and applications
- Crushing and screening
- Prehomogenization of raw materials
- Vertical and ball mill systems for raw materials
- Mechanical testing of equipment and machinery
- Industrial water
- Structural and civil engineering aspects of the cement industry
Week 05
Maintenance Certification Program
- Introduction to kiln processes
- Refractory
- Introduction to kiln processes
- Clinker coolers and clinker handling
- Coal milling and firing systems
- Cement milling
- Proactive, preventive and predictive maintenance
- Maintenance strategies
Define accurately and continuously measure student progress and knowledge
Graphing and analyzing technical and conceptual data to provide staff and organization with the tools to respond effectively to the plant’s needs, current and future demands.
Case Studies
MYSTERY OF KILN FEED FACTOR
Why Kiln Feed Factor is a mystery? It is that magic number that converts the kiln feed to clinker production calculation, which is often misunderstood,
APPLYING OPEN GEAR LUBRICANTS
APPLYING OPEN GEAR LUBRICANTS When selecting an open gear lubricant for use in a particular application, the application method must be considered. The typical methods
Maintenance Certification Program
To learn the skills needed to become a building maintenance specialist in the cement industry, students can complete a maintenance certification program. You will learn practical skills that can be applied immediately to the job role, improving productivity, maintenance quality, and overall manufacturing and production plants’ overall effectiveness.
