Session1
Aligning Maintenance with Business Goals
Don M. Barry, Associate Partner, Supply Chain Operations and Asset Management Solutions, IBM Canada Limited
9:00-9:45
Panel Discussion: Reinventing the Maintenance Manager
Don M. Barry, Associate Partner, Supply Chain Operations and Asset Management Solutions, IBM Canada Limited
Dharmen Dhaliah, Manager, Asset Management, City of Toronto
Kristopher Dominato, Maintenance Coordinator, Canadian Tire
Today, maintenance is a full-fledged business process that impacts a company’s profits, safety record, environmental compliance, costs of quality, employee health and much more. In response to this, today’s maintenance manager needs far more than the technical skills they used to begin their career. This panel discussion details the current roles and future responsibilities of maintenance in today’s organizations.
What responsibilities are there today?
Who is really responsible?
What expertise do you need to manage maintenance today?
How can you get what you need? Is there help out there?
A suggested role description for the new maintenance manager
9:45-10:30
Total Productive Maintenance
Daniel Lawson, Continuous Improvement Manager, Plant Services, Blount Canada Ltd.
Total Productive Maintenance, with its focus on getting managers, maintenance personnel and equipment users working together to prevent equipment problems and reduce expenditures, transforms maintenance into a crucial part of the business structure instead of being merely a non-profit activity. The critical tenet is to keep unscheduled and emergency maintenance to a minimum. This session will discuss the different aspects of TPM.
Benefits of an effective TPM system
TPM targets: zero defects, zero breakdowns and zero accidents
Aligning the maintenance team to priorities
Identifying causes and types of equipment failures
Implementing TPM: where to begin
Measuring TPM performance: the key to effective asset management
Communicating TPM
10:30-11:00 NETWORKING BREAK
11:00-11:45
Maintenance KPIs
Jet Singh, Manager Engineering & Facilities, Patheon Inc.
In today’s information overloaded society, there are more measures being taken throughout all types of industry than ever before. The question we need to explore is: what do we do with these measurements? This presentation will look at common measurements used in maintenance management and examine the dangers and benefits that they provide.
Are the measurements driving change in behaviour, strategy or results?
Confirming the hierarchy of measurements within the organization
Why we measure and how it is utilized
What we measure and what they drive in overall efficiencies
Work orders, inventory and physical measurements
11:45-12:30
Reliability Based Inventory Management
Don M. Barry, Associate Partner, Supply Chain Operations and Asset Management Solutions, IBM Canada Limited
Maintenance inventory is an area that many companies are looking to for cost reduction and avoidance. With new asset management strategies, maintenance can make a significant contribution to cost reduction through improved inventory. This presentation looks at optimally managing and controlling the maintenance inventory in order to provide reliability-based inventory management.
Performance measures for maintenance inventory
Investing in spare inventory and how that investment affects your bottom line
Establishing an effective spare parts evaluation program
How a reliability focus on inventory policy development will confirm what should be stocked
Practical methods for improving your inventory policy and costs
Planning and controlling your storeroom inventory effectively
Session2
Best Practices in Managing the Maintenance Function
Bruce Smith, Principal, BRS Maintenance Solutions
1:30-2:15
Ensuring Asset Life Extension Through Effective Energy Strategies
Kristopher Dominato, Maintenance Coordinator, Canadian Tire
Reducing energy consumption of equipment on the “shop floor” requires a well-thought out strategy that focuses on understanding current consumption and finding ways to reduce energy use. This discussion details Canadian Tire’s strategies for its plant and engineering facilities.
Collecting consumption information for analysis
Understanding what needs to be replaced and repaired
Determining the most effective maintenance approaches
Eliminating inefficient practices
Applying appropriate control strategies
2:15-3:00
Implementing and Managing CMMS
Varun Shrivastava, Reliability Engineer, IKO Industries
The quality of the information in the maintenance plan of the CMMS will largely determine an organization's success in increasing reliability. This discussion will examine the concept of a reliability-centred knowledge solution.
Data acquisition and data integrity
Maintenance tool kits, including a focus on content, fault diagnosis and failure prediction
Increased value in the CMMS
Performance management and information feedback
Turning data into information you can use
3:00-3:30 NETWORKING BREAK
3:30-4:00
How Does Maintenance Support Asset Management
Dharmen Dhaliah, Manager, Asset Management, City of Toronto
In the last few years we have seen the emergence of Asset Management in many industries from private to public sector. However from a maintenance management perspective it seems that AM is causing more of a confusion than anything else. There seems to be difficulties to understand what are the functions of both Maintenance and Asset Management in an organization and they co-exist to support each other. This session will clarify some of the confusions and explain how Maintenance can support Asset Management.
What is the mandate of Maintenance Management?
What is the mandate of Asset Management?
What are the links between MM & AM
How MM can support AM?
How AM can support MM?
What are the challenges being faced?
4:00-4:30
Applying Physics of Failures to Enhance Asset Reliability
Bruce Smith, Principal, BRS Maintenance Solutions
Far too often manufacturers struggle with equipment that does not perform as expected, resulting in the maintenance department being under pressure to fix frequent breakdowns and to explain why machines keep breaking. This presentation will explore how the OEM engineering design can only go so far in creating a reliable machine and investigate the 5 Reliability Killers. By understanding the causes of equipment failure we can identify how to create reliability and extend asset life.
Defining equipment reliability
Understanding a machine as the sum of its parts
Importance of design vs. application
Operating stress and its effect on parts
Uncertainty caused by handling the equipment
Importance of standardized SOPs
4:30-5:00
Maintenance Scheduling
Brad McDonald, Principal Consultant, SAP PM, Vesta Partners
With the competitive nature of today’s manufacturing, there is less tolerance for unplanned downtime. No single facet of maintenance management offers greater opportunity for savings and profit than good planning and scheduling. As such, getting control of maintenance requires an organization with a definitive planning and scheduling effort.
Prioritizing maintenance work for scheduling purposes
Developing weekly and daily schedules
Controlling and managing backlog and achieving improved customer service
Planning and installing a long-term scheduling system
Implementation of a short-term scheduling system
Planning and scheduling major repairs, shutdowns and turnarounds
Latest maintenance planning and scheduling technologies
Session3
Increased Efficiency in Challenging Times
James Reyes-Picknell, President, Conscious Asset Management
9:00-9:45
Building the Business Case for Reliability
Stephen Kenny, Director of Waste Management and Decommissioning Operations, Chalk River Labs, Canadian Nuclear Laboratories
Sometimes reliability professionals may be called upon to demonstrate the cost effectiveness of their reliability programs to management. This session will provide step-by-step instructions on how to create an effective business case for reliability.
Determining cash requirements
Presenting information in a way that management will understand
Demonstrating the impact equipment reliability has on a company's objectives
Estimating the financial contribution of reliability programs
9:45-10:30
Energy Efficient Facility Operation and Maintenance
Atiq Rahman, Manager, Facility Maintenance, City of Markham
This discussion will include strategic planning and key approaches to:
Understanding of building requirements
Identifying energy efficiency opportunities in Facility Operation
Long-term life-cycle planning
Energy retrofits
Case studies
10:30-11:00 NETWORKING BREAK
11:00-11:45
Hiring Skilled Trades
Jerry Dover, Director of Engineering and Maintenance, Give and Go Prepared Foods
The percentage of maintenance workers in the manufacturing sector over the age of 55 has grown significantly in recent years, increasing the chances of skill shortages and high costs of replacing veteran employees after a wave of retirement. This session will examine practical strategies for hiring skilled workers.
Best practices for recruiting competent job applicants
Addressing knowledge transfer from experienced to less experienced employees
Sustaining expertise and competitive edge with key hirings to stem the tide of retirement
Use of mentoring programs
Strategies for ensuring new hires will be a good fit
Conducting a thorough job analysis for each position
Implementing an effective employee orientation and training program
11:45-12:30
Optimizing Asset Management 2.0
James Reyes-Picknell, President, Conscious Asset Management
Maintenance departments everywhere are moving away from their traditional “break and fix” approach to one that focuses on optimizing the effectiveness and efficiency of production assets. This discussion details how to develop an effective asset management plan for the maintenance function.
Conducting an inventory of all production assets
Leveraging reliability techniques in the development of maintenance
Requirements and schedules
Prioritizing and scheduling life-cycle activities
Revising the plan in response to new information
12:30-1:30 Lunch
Session4
Effective Asset Management
Liane Harris, President, ECS2 Group Inc. (Machine Healthcare)
1:30-2:15
Effective Information Modeling in Asset Management
David Armstrong, Senior Reliability Practioner, Bentley Canada
This discussion details the importance of information modeling to ensure a continuous program for reliability, integrity and performance of an asset, including:
Developing a common collaborative process
Managing the flow of data
Optimizing decisions on budgeting for equipment maintenance and replacement
2:15-3:00
Lean Maintenance: Lean Planning & Scheduling
Garvit Rawat, Business Unit Leader, Planning/Scheduling/MRO (Maintenance & Reliability), Mondelez International Inc.
While many companies have implemented the most common lean maintenance tactics, in most cases, they have failed to achieve their overall objectives. The key to achieving lean maintenance objectives is to implement effective planning and scheduling. This will ensure that maintenance tactics work is carried out in the minimum amount of time with the highest labour productivity. It requires addressing the work culture, reengineering the organizational structure and providing adequate software support.
Benefits of effective planning & scheduling
Organizational challenge
Planning and scheduling roles
Measuring the results achieved for continuous improvement
3:00-3:30 NETWORKING BREAK
3:30-4:00
Linking Maintenance Strategy With Operations
George Illaszewicz, Asset Management Engineer, Associated Engineering
Today, maintenance must add value to business in terms of quality, capacity and availability, thereby leveraging the company in the marketplace. To play this role, the maintenance department must develop best practices with significantly less manpower. This presentation will discuss how to link maintenance strategy to overall operations.
Incorporating reliability excellence as a business strategy
How maintenance and reliability can create value
Running the warehouse like a business
How to establish a proactive asset management strategy
Developing action plans required to support business goals and objectives
4:00-4:30
Preventive vs. Emergency Maintenance
Liane Harris, President, ECS2 Group Inc. (Machine Healthcare)
Preventive maintenance techniques are used to establish required servicing and inspection periods so that equipment shutdowns can be more effectively scheduled and planned, resulting in longer equipment life, fewer breakdowns and smoother operation, planning & scheduling. This discussion compares the benefits of a PM system versus emergency maintenance.
Designing a PM program: preventing the failure of equipment before it actually occurs
Preserving and enhancing equipment reliability by replacing worn components before they actually fail
Conducting equipment checks, partial or complete overhauls at specified periods
Keeping a record of equipment deterioration
Technological advances in tools for inspection and diagnosis
Controlling the cost of preventive maintenance
4:30-5:00
Effective Metallurgical Failure Analysis
Shane Turcott, Principal Metallurgist and Failure Analyst, Steel Image Inc.
Production equipment failures can result in costly production losses and safety hazards. Determining the precise cause of component failure is critical for developing cost-effective solutions to prevent repeat occurrences. This discussion details the processes used during metallurgical failure analysis.
Identifying causes of failure
Laboratory tools used to investigate post-failure
Preventing recurrence of similar failure or accidents in the future
Improving facility reliability
Integration with root cause failure analysis techniques