Presented by:

The Results Oriented Reliability and

Maintenance Management Seminar

The “what good looks like” Seminar

Sept. 20 - 23, 2010 – Metro Manila, Philippines
Venue: The Prestige Tower, Ortigas Center Pasig City

This seminar will bring Operations, Maintenance and Engineering

closer together to form a “good” reliability maintenance partnership.

Production line
speed must increase
We need to to meet production We need more
be under budget volume targets. downtime to perform
for 2010. our maintenance.
Meet the Presenter

Tor Idhammar
Partner and Vice President
IDCON, Inc.
He has worked in over 60 organizations in 13 countries in industries such as food, pulp and paper,
mining, steel, oil and gas, chemical, and discrete manufacturing. Before working with IDCON, INC,
he has experience from supply chain consulting with MA-systems and has served the Army. He
possesses a Bachelors of Science in industrial engineering from North Carolina State University and a
master of Science in mechanical engineering from Lund University, Sweden.

IDCON, Inc. – Maintenance Management Consultants

Since the inception of Idhammar Konsult AB of Sweden in 1972, we have provided a range of maintenance management
consultant services for our clients.

IDCON, INC is a highly specialized management consultant firm working within the
industry to maximize productivity through improvement in maintenance and operations practices. All consultant services
are based on the Results Oriented Reliability and Maintenance™ (RORM) philosophy. This philosophy has been devel-
oped by IDCON, INC over the years through project experience in the industry.

Our Products
As maintenance management consultants, our products include education, training and implementation (consultant ser-
vices) support covering:
• Current Best Practices (CBP) A training and • Root Cause Problem Elimination
assessment exercise • Results Oriented Reliability and Maintenance seminars
• Planning and Scheduling of maintenance work • Maintenance books, reliability books
• Preventive Maintenance/Essential Care and • Operations and Maintenance Productivity Simulation
Condition Monitoring • Annual Reliability and Maintenance Conference
• Basic Equipment Care for Operators • International Reliability and Maintenance
• Spare Parts management Benchmarking Expedition

Global Expertise
Our approach, as maintenance management consultants, has been successfully applied in different industries in 43 coun-
tries within North America, South America, Europe, Asia and Australia.

IDCON, INC, Maintenance Management Consultants in Different Industries

Our approach has been successfully applied in various industries such as: pulp and paper, steel, chemical, aluminum and
mining. It has also been applied in the Fortune 500 manufacturing, automotive, electronics, utilities, food, and forestry
products industries.

Impact the Bottom Line

All of our products are designed to have a significant impact on the bottom line and generate substantial financial benefits.

Compatibility
Our services and products have been successfully implemented and integrated with Total Productive Maintenance (TPM),
Reliability Centered Maintenance (RCM), ISO 9000, Total Quality Management (TQM) and other maintenance and im-
provement concepts.

www.idcon.com
Day 1
Results Oriented Reliability and Maintenance Management
Course Outline: Results Oriented Reliability and Maintenance Management
The purpose of seminar is to educate operations, maintenance and engineering in what good reliability and maintenance
practices are and “what good looks like”. The theme of the seminar is built up around how Operations, Maintenance and
Engineering can work closer in a reliability partnership.

The seminar serves as an overview for all IDCON training programs and as a catalytic tool to help your organization dis-
cover and agree on improvement opportunities and what actions must be taken to close the gap between best practices
and the way you work today. The Seminar content also includes examples on how you can achieve improvements.

Implementation of the discoveries from the seminar will result in increased quality production throughput and lower costs.
This will be achieved through a better partnership between Operations, Maintenance, Engineering and other support func-
tions such as stores.

Master new knowledge that will last a lifetime:

• Understand the whole picture of how to achieve cost effective reliability
• Learn how to calculate financial impact of equipment reliability for your company
• Realize the new roles of operations, maintenance & engineering to achieve improved reliability
• Learn how different organizational structures may work
• Understand what good reliability and maintenance looks like
• Discover the power of identifying production bottlenecks and the reliability impact on those bottlenecks

Who will benefit from this training:

Maintenance managers Plant Managers
Maintenance supervisors Vibration specialists
Maintenance superintendents Predictive maintenance specialists
Maintenance or manufacturing engineers Lubricators
Engineer Lubrication Engineers
Engineering Managers Operations managers
Maintenance Planners Corporate Vice Presidents

This seminar will cover the following topics:

• The development of reliability and maintenance • What best performers do better than others
in industry • Partnership work system between operations,
• Automation’s impact on maintenance maintenance, engineering and stores
• Capacity of industry vs. number of workers • Roles and responsibilities, common goal, and work
• Case studies of improvements in reliability practices in a partnership organization
and maintenance • Best reliability and maintenance practices methodology
• Improving equipment reliability is about changing people to identify improvement opportunities; develop
and work systems improvement plans, guide implementation and measure
• The right people in the right spot progress of implementation and results
• Operations role in reliability • Maintenance prevention
• Maintenance role in Reliability • Condition Monitoring
• Engineering role in reliability • Planning of work
• Maintenance philosophies available and what they are • Scheduling of work
• Mobility of management requires stronger work systems • Interface with stores
• What manufacturing reliability is and how to measure it • Technical database requirements
• Overall Production Effectiveness (OPE) • Optimization of preventive maintenance between
operations and maintenance
• Mean time to break-down
• Root cause problem elimination
• Life Cycle Cost, maintainability and reliability design
• Measure the processes with Key Performance
• Better reliability and impact on safety, revenues and cost.
Indicators (KPI’s)
• Example: How much Is 1% improved reliability worth for
the company
Days 2 & 3
Preventive Maintenance/Essential Care and Condition Monitoring

Learn the basic concepts to prevent and detect early equipment failures from the perspective of operations and mainte-
nance. Discover how operations process care relates to maintenance equipment care. Do you want a better understanding
of the design of a cost effective preventive maintenance system for operations and maintenance? This seminar will include
a discussion of a failure developing period, life of components and consequence of failure analysis.

Master new knowledge that will last a lifetime:

• Learn how to cost effectively optimize your preventive maintenance program
• Understand available techniques for preventing failures
• Learn about all available condition monitoring options
• Practically practice documenting full preventive maintenance tasks for equipment
• Discover how to financially prove results from preventive maintenance
• Learn the reliability basics such as equipment life, failure developing, and different maintenance methods
• Find out about the different implementation steps for improving preventive maintenance in your plant

Who will benefit from this training:

Maintenance managers Plant Managers
Maintenance supervisors Vibration specialists
Maintenance superintendents Predictive maintenance specialists
Maintenance or manufacturing engineers Lubricators
Engineer Lubrication Engineers
Engineering Managers Operations managers
Maintenance Planners

Course Outline
Overview Alignment for operation
• Definition of Maintenance • Why align
• Do the right thing or do things right – are you focusing • Alignment basics
on the right things? • Understand how to detect misalignment
• Mission of PM/ECCM improvement • Misalignment effect on bearing life
• Goal of PM/ECCM improvement
• Example of plant goal and mission statements statement Operating Procedures
• Definition of Failure • How operating Procedures effect equipment reliability
• Definition of Break Down • Examples: Parallel Systems
• Definition of Failure Source • Thermal Growth
• Definition of PM/ECCM • Water Hammer
• Exercise develop PM/ECCM definition
Bearings, Vibration and SPM
Detailed Cleaning of Equipment • Speed Increase and bearing life
• Detailed Cleaning Impact on Reliability • Load increase and bearing life
• Motor life • Exercise – calculate bearing life reductions while
• Inspectability changing load and speed
• Mind set for detailed cleaning, what is clean • Lubrication, dirt, alignment problems combined
• Shock Pulse Measurement
Lubrication/Hydraulics for operations • Vibration Pen
• Lubrication basics and purpose of lubricants • Vibration Analysis
• Types of Lubricants • Other inspection tools
• Defining the measurements of oil cleanliness
• A micrometer – measurement for filtration Couplings & stroboscopes
• How dirt enters systems • Coupling types
• How dirt effect component life • Inspection of couplings
• Filter ratings • Stroboscope basics
• Water in Oil • Exercise - Inspection of gear coupling
• Oil/ grease inspection methods
• Oil/ grease inspection tools
• Implementation of better lubrication practices
Days 2 & 3 continued
Preventive Maintenance/Essential Care and Condition Monitoring

Chain, Belt & Guards Implementation of a better PM/ECCM process

• Belt Basics • Financial results
• Chain inspection • Cut cost and/or increase reliability
• Belt inspection • Charter/ Mission/ Goal
• Tensiometer • How to benchmark current performance
• Ultrasonic inspection • How does PM/ECCM affect RCFA/Planning/
• Sheave guides Scheduling/Database/Stores
• Motor shelf • What is the biggest opportunity in your plant?
• Assessment of your plant
Material crack detection
• Dye Penetrant Reliability Basics
• Ultrasonic • Essential Care
• Eddy Current • Maintenance methods Operate to Break Down
• Magnetic powder • Maintenance method Fixed Time Maintenance
• Maintenance Method Condition Monitoring
Corrosion & Heat exchanger • Expected life of components
• Corrosion • Failure developing period
• Galvanic Corrosion • Selection of most cost effective maintenance method
• Heat exchange inspections • Consequence of failure analysis
• Exercise – Heat exchanger inspection • Example Financial Calculation comparing Maintenance
Method Costs
Temperature Inspections
• Stickers Document PM/ECCM
• Infrared gun • What is a route?
• Crayons • What are shut down PM’s?
• Infrared Camera • Decide PM/ECCM activities for sample equipment
• Examples applications for infrared cameras • Who should inspect equipment?
• Exercise: IR-Gun ration calculation • Decide inspection tools to use
• Software/ Hardware requirements
Pumps and Mechanical Seals • Organize PM/ECCM in comprehensive format for users
• Pump Basics • Reporting of PM/ECCM performance
• Cavitation • Exercise: Do financial calculation and decide what
• Seal types: Mechanical, packing, dynamic seal maintenance method to use
• Seal inspections • Exercise: Document PM/ECCM for selected equipment
• Exercise: Set up a PM program for a centrifugal pump.

Leaks
• Cost of water leaks
• Cost of steam leaks
• Cost of air leaks
• Leak inspection – Ultrasound tools
• Leak detection – smoke
• Leak detection – soap water
Day 4
Root Cause Problem Elimination
Course Description
IDCON’s Root Cause Problem Elimination training focuses on eliminating problems rather than just analyze them as the
case is in the traditional RCFA. IDCON brings root cause analysis into your day-to-day reliability management process by
integrating root cause into your current processes in a cost effective manner.

The training is a very unique class that primarily focuses on teaching all people in an organization the correct thinking
behavior before teaching the documentation method to use. The training is based on fundamentals of critical and creative
thinking applied to the root cause and troubleshooting processes. The thinking processes are used as a base when we
are applying root cause to the different documentation methods. Your organization may use logic trees, fishbone dia-
grams, cause and effect charts or a specifically branded supplier documentation method. We can work with any of these
to make your current process more effective. IDCON can also let you select a documentation method of your choice and
use that method in our class.

Key Learning Points

• Understand the mechanics of solving problems effectively
• Get introduced to the basics of critical and creative thinking
• Understand different ways to implement a root cause process in your organization
• Understand pros and cons for basic documentation methods such as logic trees, cause and affect analysis, fishbone
diagrams, why-why, etc
• Understand how root cause becomes effective in your reliability program together with planning and scheduling,
preventive maintenance, and technical database.
• Practice root cause analysis through exercises in the classroom.

Who should attend?

The root cause problem elimination training is very useful to anyone in an organization that solves problem. This means
more or less all in an organization. Some of the key people to attend are:

Plant Managers Maintenance Planners

Maintenance managers Vibration specialists
Maintenance supervisors Predictive maintenance specialists
Maintenance superintendents Lubricators
Maintenance or manufacturing engineers Lubrication Engineers
Engineers Operations managers
Maintenance and reliability engineers Operators
Engineering Managers Operations supervisors

Course Outline
• Learning Objectives
• People are NOT “Natural Problem Solvers” – example of what usually happens – Tank Bubble Pipe problem from a plant
• Sample well known problems that made the news with catastrophic effect
• Root Cause Definitions
• Basic Beliefs: Possible Discussion
• Why RC problem elimination not failure analysis
• An Excellent RCPE process need basic PM and PS – Why?
• An example: Electronic Board Failure – How deep do we dig?
• An example: Gear box failure on a vacuum pump drive train
• Doubts when going through root cause in example above – Why dig deeper, why verify?

Process Overview
• Root Cause Process Overview
• The Individual Thinking Process vs. Overall Plant Process
• Do you see problem – black hat thinking! Is this really OK?
• Why follow a thinking process? Isn’t it an overkill – Exercise find the F’s will illustrate that it isn’t
• Exercise II – You think in engraved patterns Car and person
• Types of Problem we encounter, three typical examples: Routine, Linked, Major events
Day 4 continued
Root Cause Problem Elimination
Root Cause Thinking Specifying the Problem
• When you see something wrong what do you do?
• Facts / Information Collection Checklist
• Problem Statement
• Exercise: Joe’s Problem Statement
• Exercise: Sample Problem Statements. Good or Bad?
• Exercise: Plant Problem – develop Problem Statement
• Exercise: The Cards
• More about collecting facts
• White hat thinking
• Distinguish between Facts and Information – this is a fact because….
• Using digital camera for collecting facts
• Sources for collecting facts
• Documenting facts using a simple list (optional tree, fishbone, whatever you prefer?)

Root Cause Thinking - Developing Possible Causes

• Look for Changes in time
• Look for Similar items – do they have the same problem?
• Frame the problem – Don’t stray too much
• Coming up with possible causes requires CREATIVE THINKING – Green Hat
• Example: Changes in time, possible plant example?
• Example: Similar Objects, possible plant example?
• Possible Causes List

Root Cause Thinking- Select Most likely Cause

• Compare each possible Cause with the facts in your lists
• Show process with example, possible plant example
• Did you make Assumptions? How to handle assumptions

Identify Possible Solutions

• Slow down. Are there more than 1 possible solutions?
• Example: Vacuum pump
• Evaluating Ideas: Green, Black, then Yellow

Thinking about Thinking

• Why one step at the time? We THINK better doing one thing at the time
• Critical Thinking
• Creative Thinking
• Exercise – 3 People enter a hotel
• Example: Do we base our opinions and decisions on facts or fiction?
• Bearings on Press arms
• The technique of the 6 thinking hats
• Suggested RCPE beliefs for Plant

Implementing the Business Process of RCPE in the Plant

• Trigger – when do you start, go through, and/ or finish a RCPE
• Integrate Preventive Maintenance with RCPE
• Implementing the suggested Solution – the hardest part to get done
• Preparing and selling the solution
• An Example of Elimination vs. Analysis – the resin tank
• Suggested work flow for RCPE

Documentation options other than the list

• Why-Why advantages and disadvantages
• Fishbone advantages and disadvantages
• Logic Tree advantages and disadvantages
• Cause and effect advantages and disadvantages
Registration FAX YOUR COMPLETED FORM(S) TO: +63 2 726 5461

Seminar Costs
Conference Registration: USD $1669 (plus 12% VAT)

Three Easy Steps To Register:

1 How many people are you registering for this conference?
I am only registering one person for this conference
I am registering more than one person to be billed on the same invoice; there will be registrations total
*make a copy of this registration form for each additional person.

I am registering more than one person to be billed on separate invoices; there will be registrations total
*make a copy of this registration form and complete all sections for each additional person

2 Registrant Information (all fields must be completed)

Name: Title:

Company Name: Type of Business:

Address:

Office Phone: Mobile Phone:

FAX: E-mail:

Invoice Attention to:

Approving Manager’s Name: Title:

Approving Manager’s Signature:

3 Payment Please deposit check payments to account name/payee: Kontrakwerke, Inc. at Chinabank
Fax your completed form(s) to: +63 2 726 5461 Acct. No. 134-040121-6 (peso) or
Acct. No. 134-702721-1 (dollar)

Hotel Information
The Richmonde Hotel For reservations, please make your bookings directly with the hotel. To enjoy special room
21 San Miguel Avenue rates, please quote CRE Philippines Corporate Rate.
Ortigas Center, Pasig City
Metro Manila, Philippines Hotel bills are to be settled by delegates directly with the hotel. Hotel reservations and
Tel: (632) 638-7777 travel arrangements are the responsibility of the registrant. Please note that rooms are
Fax: (632) 638-8567 available on a first come, first serve basis.
www.richmondehotel.com

Conditions
Terms of payment: Following completion and return of the order form, full payment is required at least 2 weeks before the scheduled training. Receipt will be issued on payment. A
50% cancellation fee will be charged under the terms outlined below. We reserve the right to refuse delivery if payment is not received on time. Unless otherwise stated in the invoice.
Payment may be made in US dollars or in Philippine Peso. The client agrees with the payment terms of Kontraktwerke, Inc.
Substitution and Cancellation: Provided the total fee has been paid, substitutions are allowed at no extra charge f earlier than 14 days before the workshop. Substitution within 14
days before event-date will be allowed subject to an admission fee equal to 10% of total fee. Otherwise all purchase order carry a 50% cancellation liability immediately after signed sales
contract has been received by KWI Phils. (as defined above). Cancellation must be received in writing by mail or fax six weeks before the conference to be held in order to obtain a full
credit for any future KWI Phils. trainings. Thereafter, the full fee is payable and is non-refundable. The service charge is completely non-refundable and non-creditable. This serves as a
sales contract. By signing this contract, the client agrees that in case of dispute or cancellation of this contract KWI Phils. will not be able to mitigate its losses for any less that 50% of the
contract value. If, for any reason, KWI Phils. decided to cancel or postpone this workshop. KWI Phils. is not responsible for covering airfare, hotel or other travel costs incurred by client.
The fee will not be refunded but can be credited to a future scheduled workshop. Event program content is subject to change without prior notice.
Companies that have benefitted from IDCON training:

ABB International Paper Stora Enso

Akzo-Nobel Iron-Ore Swedish Steel (SSAB)
Alberta Pacific Kaiser Aluminum Tembec
Alcoa American Home Foods Kimberly-Clark UPM – Kymmene
Arch Coal, Lafarge Walker Systems
Arizona Chemicals Louisiana Pacific (LP) Weyerhaeuser & Willamette
Bahlsen Quality Foods LTV Steel Whirlpool
Beyond Petrolium Marathon Oil Fresh Express
(previously known as British Petroleum) MeadWestvaco Glanbia Foods
British Oxygen Company (BOC) Nexen Xtrata Copper
Buckeye Norbord Europe & N.A Tesoro Refining
Conagra Foods Norsk Hydro Cellulosa Arauco
DeVault Foods Novozymes Thilmany
Dofasco Steel Oil Sand Extraction company Kapstone
Flexsys Ponderay Newsprint Agrium
Fonterra - New Zealand Procter & Gamble US Silica
Giant Cement Rohm & Haas Dairy Concepts
Graphics Packaging SAPPI Georgia Pacific
Hewlett Packard Scotts fertilizer Tarkett
Hibbing Taconite Smurfit Stone Holmen
ICL SP Newsprint Kazakhmys Corp.

IDCON Reliability & Maintenance Books Sign up for IDCON’s Maintenance

IDCON is a management consulting company Management Newsletter at
that specializes in helping industry maximize www.idcon.com/newsletter.html
profits by improving reliability and
maintenance practices.
The eight books are a unique collection
developed by consultants who have
spent their life working in industry. The
books focus on practical hands-on tips
and techniques.

To order online go to www.idcon.com and click on Bookstore or call

us at 800-849-2041!

Please direct any questions about the seminar to:

Erwin D. Bernal Torbjorn Idhammar

Training Consultant President
CRE IDCON, Inc.
3/F 718 Leeleng Bldg. Shaw Blvd. 7200 Falls of Neuse Road
Mandaluyong City, Philippines 1552 Suite 200
Tel: +63 2 723 7767-70 Raleigh, North Carolina 27615 USA
Fax: +63 2 726 5461 Tel:+1 919 723 2680
Fax:+1919 7232529
[email protected]
www.idcon.com