6741912e-0fb2-41d8-b056-7d1c40b4d634_200x200

Maintenance Certification Program

Success in the cement industry depends on constant differentiation, evolution and innovation, as well as 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 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 effective 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 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 key 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 and 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 effectiveness of manufacturing and production plants. 

This certification program is focused on the relevant maintenance engineering issues, concentrating maintenance guidelines with other disciplines, resulting in the management of assets and their functions. The program combined theory and hands-on application for the cement industry of the most relevant topic and components needed to become a maintenance specialist or future maintenance managers and professionals responsible for building and sustaining a world-class maintenance program.

Training Program Objective

Help the maintenance staff improve productivity and the quality of the workforce; anticipating and eliminating possible delays, quantifying the risk and preventing 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 effective maintenance budget.

Organizational benefits

IMPROVED AND EFFICIENT WORK PRACTICES STABLE, EXPERIENCED, WELL TRAINED AND HIGHLY SKILLED WORKFORCE REDUCED WASTE OF TIME AND RESOURCES IMPROVED PLANT EFFICIENCY MAINTENANCE MOTIVATED STAFF INCREASED SATISFACTION LEVELS ENHANCED EQUIPMENT LIFE IMPROVE OVERALL EQUIPMENT EFFECTIVENESS

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 needs of the plant, as well as current and future demands.

Case Studies

PERFORMING A CEMENT PLANT OPERATIONS AUDIT

PERFORMING A CEMENT PLANT OPERATIONS AUDIT The cement plants and process engineer (due to training and job title) is frequently asked to examine the “big

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 effectiveness of manufacturing and production plants.

To know more about Maintenance Certification Program implementation