For over 25 years, Asset Schools has been sharing the knowledge of subject matter experts to help maintenance and reliability teams build competency and develop capability.
From deep, technical skills training to strategic asset management concepts, we’ve got you covered with public, onsite, or online courses. Courses are interactive and founded in extensive case history. Participants gain practical insights and tools that can be immediately applied to their work.
The recognition of our courses for Continuing Professional Development (CPD) participation ensures that the time invested in Asset Schools contributes to career advancement, ongoing professional growth, and development.
Training Courses
• Planners’ School Level 1
• Planners’ School Level 2
• Supervisor School
• Reliable Assets School
• Asset Management School
• Asset Management Fundamentals
• Shutdown School
• MRO School
• Precision Maintenance School
• Sustainable Assets School
• Lubrication School Level 1
• Lubrication School Level 2
• Lubrication Awareness
• Lubrication Fundamentals
• Vibration Analysis Level I
• Vibration Analysis Level 2
• Vibration Analysis Level 3
• Switch On: Safety Leadership
Planners’ School
LEVEL 1
Level 1 (Fundamentals of Work Management) is an introductory level, suitable for planning practitioners who are starting out or for those wanting to brush up on the basics.
8 Core Modules
• Work Management And Business Imperatives
• Identifying Work
• Maintenance Planning
• Maintenance Scheduling And Dispatch
• Maintenance Work Execution
• Spares Management
• Transitioning From Breakdown Maintenance
• Performance Assessment And Measurement
Course outline
Work Management And Business Imperatives
• Business objectives and the maintenance strategy
• Annual and monthly budget controls
• Work flow – defining all the processes
• Stakeholders
• Performance measurement and continuous improvement
Identifying Work
• Nature of work and what initiates it
• Specify new work and user priorities
• Approval of work – technical and commercial approval
• Back log and risk reporting
Maintenance Planning
• Initial Estimation and the Forward Log
• Scoping: Interface between the Supervisor and the Planner
• Detailed Planning and using the Work Management System
• Specifying materials, resources, tools etc
• Requirements of a Work Order
Maintenance Scheduling And Dispatch
• Forecasting and committing the PM schedule
• Using the Forward Log and resource balancing
• Opportunistic work
• Handling work not done
• Standard meetings and work dispatch
Maintenance Work Execution
• Coordinating work and work site access
• Monitoring the work site and technical support to the team
• Handling urgent and emergency work
• Work order close out
• Financial reconciliation
Spares Management
• Supply management processes
• Catalogue and inventory
• Stock control
• Staging parts
• Goods issues and returns
Transitioning From Breakdown Maintenance
• Managing change
• Establishing the plant listing
• Statutory obligations
• Job Plans
• PM schedules
Performance Assessment And Measurement
• KPIs
• Response to KPIs
• Auditing
• Management reporting and strategy improvement
What you can expect to take away
1. Review the organisational design and clarify roles for different stakeholders
2. Improve communication between planners, supervisors and operations
3. Understand what the asset information system has to provide and how to set it up
4. Register plant and equipment correctly to ensure they are covered by the maintenance system
5. Improve planning of work to deliver labour efficiencies
6. Tune the preventive maintenance strategy to reduce failures with optimal procedures
7. Ensure parts management supports work on time with minimal stock holdings
8. Align your maintenance and production schedules ensuring cost-effective access to equipment
9. Deliver cost reduction through improved labour utilisation and proactive maintenance
10. Resource scheduling to better package work and optimise availability
11. Transition from breakdown maintenance to planned maintenance
12. Correct management of engineering stores
13. Develop meaningful KPIs and act on them
14. Accurately analyse your risks and costs
15. Implement a continuous improvement program that involves all stakeholders working together
Planners’ School
LEVEL 2
The course builds on Planners’ 1 and explores why and how we plan and how work delivery can be optimised with existing teams, systems, and approach to work management. It explains the quality expectations of planning and scheduling which supports the field teams to help them deliver a great job. This includes consistency, tracking performance and ensuring people understand the expectations of their role.
8 Core Modules
• The Enterprise Asset Management System
• Master Data Management
• Configuration Management
• Budget Management
• Planning Standard
• Schedule Management
• Team Coordination
• Performance Measurement
15 hrs over 2 days
15 hrs over 2 days
Course outline
The Enterprise Asset Management System
• Elements of the EAMS
• Links to other systems
• Competencies and access to the system
• Contractors and the EAMS
• Reporting tools
Master Data Management
• Assets
• Preventive maintenance
• Supply and materials
• Safety and permits
• Inspection management
Configuration Management
• Purpose of configuration management
• Configuration control
• Configuration auditing
• Configuration change
• Maturity in configuration management
Budget Management
• Annual works plan
• Provisions
• Monthly budget control
• Cost tracking in works delivery
• Management of contract expenditure
Planning Standard
• Requirements for specifying work
• Work scope management – managing specification of work plus stored jobs
• Materials management – consumables, stock and direct purchase
• Safety management and permits control
• Rough cut scheduling – work priorities, procurement and earliest start dates
Schedule Management
• Roster management
• Scheduling access including outages/turnarounds access plus parent jobs
• Schedule loading and resources levelling
• Forward log consolidation and standard meetings/approvals
• Schedule lock and reporting
Team Coordination
• Effective communication for teams to control work
• Weekly run sheets
• Balancing work in a week/daily scheduling
• Managing break-in work
• Handling work not started
Performance Measurement
• EAMS blueprint compliance measures
• Budget reporting
• Critical spares management
• Scheduled work delivery
• Plant reliability risks
What you can expect to take away
1. The next body of information and training which builds on Planner 1 introductory concepts and looks out how work delivery can be optimized with existing teams, systems and approach to work management. Basically what next to improve work management?
2. The set up of the work management information system to enable modern-day, effective work delivery. If we do not get these principles right, then we are badly handicapped in delivering the right work at the right time.
3. Using data to help understand risk in the assets and risk associated with how work is delivered, which then will drive continual improvement. What is the story that data is telling us about our assets?
4. Quality expectations of planning and scheduling which supports the field teams to help them deliver a great job. Quality means consistency, tracking performance and ensuring people understand the expectations of their role.
5. Working with teams where different people have different values, different responsibilities and need to achieve outcomes specific for their role. How do we work together, communicating the current issues and celebrating where the team has successes?
Supervisor School
This course assists supervisors of maintenance teams with their dual purpose: to ensure that work by the maintenance teams is delivered safely on time and with requisite quality; and to provide immediate advice back to the organisation on equipment-based risks which can lead to operational downtime. The first is an essential leadership role and the second recognises that supervisors must have the appropriate technical knowledge and experience to understand the equipment their teams work on. Participation in this course will help supervisors balance their time between administration duties that support their team and its workflow with walking the sites, observing potential problems and driving continual improvement.
8 Core Modules
• Leadership in Work Management
• Managing New Work
• Supervision in Maintenance Workflow
• Reporting for Supervisors
• Delivering the Maintenance Strategy
• Workplace Observations
• Improving the Team
• Personal Improvement
Course outline
Leadership in Work Management
• Leading people and communicating goals
• Safety management in everything we do
• Moving on from breakdowns and continuous urgent work
• Prioritising the time of a supervisor – what is a good day
Managing New Work
• Assessing risk to be addressed by new work
• Job estimation and scoping
• Making the case for the required date
• Coping with break-in work and shifting to planned work
Supervision in Maintenance Workflow
• Value of long term schedules for the team
• Protecting the schedule for the week
• Placing the right work with the team members
• Ensuring necessary feedback from completed work
Reporting for Supervisors
• Standard reports used by supervisors
• Purpose of kpis and explaining them to the team
• Using reports in standard meetings and team communications
• Special investigations and who can help with information
Delivering the Maintenance Strategy
• Understanding fmea and pm development
• Importance of good maintenance practices
• Stop the tick and flick pm
• Understanding and then acting on risks identified by inspections
Workplace Observations
• Identifying and acting on safety risks
• Planning and work delivery quality
• Using information from job observations
• Enhancing team awareness
Improving the Team
• Addressing maintenance induced problems
• Leading a united team for effective work
• Improve equipment performance and reliability
• Implementing team improvement plans
Personal Improvement
• Role of the supervisor in continuous improvement
• Improving the performance of a maintenance department
• Managing stakeholders and their needs
• Improvement plans for supervisors
What you can expect to take away
1. Clarify front line leadership obligations to ensure safe work sites that deliver quality work every time.
• Principles of personal leadership.
• Engagement and communication of the team.
• Clear personal objectives for improvement.
2. Work with engineering, planning and other departments to drive improved maintenance procedures that are efficient and identify risk in the equipment.
• Avoiding tick and flick PMs.
• Improving feedback with measurements.
• Raising condition-based work requests resulting from the inspections.
• Ensuring servicing, lubrication and other standard work prevent unnecessary failures.
3. Appreciate the leadership role of supervisors in priming the workflow pipeline and ensuring a good flow of work through to planning and scheduling.
• Prevent break-in work.
• Ensure a good pipeline of useful work to stop failures and improve equipment.
• Participate in estimating and scoping work leading to effective job plans.
• Work with schedules to ensure the right priorities are being met including aged work, long-term adjustments and repairs etc.
4. Develop personal plans for individual improvement, uplift in team performance and ongoing equipment improvement.
• Working with information and understanding the implications of standard reports.
• Engaging with team members to develop a unified approach to improvement.
• Identifying and addressing wasteful practices, either imposed on the team through the maintenance strategy or within the team as they deliver work.
Reliable Assets School
Where data and reliability engineering meet planning, maintenance, and work management. Designed to assist in your understanding of the total approach to ensuring assets deliver their required level of reliability and performance throughout their operational life. This course will assist individuals who wish to understand more about improving the performance of their assets and deliver long term, sustainable benefits.
8 Core Modules
• Work Management And Reliability Improvement
• Reliability And Continuous Improvement
• Operator Care
• Improving The Maintenance Approach
• Inventory Analysis And Obsolescence
• Condition Monitoring
• Handling Data
• Defect Elimination
15 hrs over 2 days
15 hrs over 2 days
Course outline
Work Management And Reliability Improvement
• Reliability improvement in workflow
• Stakeholders delivering reliability
• Determining opportunities for improvement
• Developing and prioritising the improvement plan
Reliability And Continuous Improvement
• Reliability framework
• Issues register
• Condition assessments
• Investigations
• Defect analysis
Operator Care
• Principles of Operator Driven Reliability (ODR)
• Front line observation
• Improving operator communication
• Autonomous maintenance
Improving The Maintenance Approach
• Elements of Preventive/Predictive Maintenance
• Asset criticality
• FMEA
• Improvement techniques – RCM, TPM, PMO
• RBD analysis of systems
Inventory Analysis And Obsolescence
• Stock out analyses and minimum holdings
• Critical spares analysis
• Obsolescence management
• Alternative supplier analysis
Condition Monitoring
• Condition monitoring framework
• Overview of technologies
• Using condition monitoring data
• Achieving value from condition monitoring
Handling Data
• Work order history
• Managing inspection data
• Forecasting future problems
• Reporting maintenance effectiveness
Defect Elimination
• Root Cause Analysis
• Handling evidence
• 5Y
• Fishbone analysis
What you can expect to take away
1. What does a good organisation look like in how it structures its operations, maintenance, reliability, supply, engineering and asset management teams?
2. Embedding continuous improvement in the delivery of maintenance work –defining the right work to prioritise and how to enable the improvement process
3. Team work between maintenance and reliability – how the two teams support each other and deliver measurable improvement
4. Understand the nature of data and how to read different kinds of reports – single measurements, time trends and spectral
5. Setting up a condition monitoring system in a structured way – what information to manage, standards to follow and what should be the intended outcomes?
6. Assessing the return from condition monitoring and if it is delivering the expected benefit
7. Reviewing a detailed reliability report – what is advised on where to improve critical plant and what are the problems which need to be addressed?
8. How a reliability engineer uses data to forecast improvements in complex equipment if changes are made to its design or maintenance
9. Total strategy for defect elimination through analysing failures, RCA, 5Y and fishbone analysis for multi-cause incidents
10. Using FMEA to improve the preventive maintenance strategy – what is a practical approach and what reports does it provide to lift reliability performance?
11. Implementing ten principles of Operator Driven Reliability to address simple preventable defects in the assets
12. Undertaking front-line observations of possible problems and what to look out for
Asset Management School
Asset Management School will assist individuals who wish to understand how to prioritise their expenditure, set up teams for both strategic and tactical success, and ensure they work well with other stakeholder groups associated with the overall business performance of the assets.
8 Core Modules
• The Application Of Asset Management
• Understanding The Organisation
• Specifying Asset Management Strategy
• Using Asset Management Plans
• Condition Assessments, Life Cycle Costs And The Capital Plan
• Feasibility Studies, Commissioning And Life Cycle Implications
• Operations, Maintenance And Reliability
• Continual Improvement In Asset Management
15 hrs over 2 days
15 hrs over 2 days
Course outline
The Application of Asset Management
• Aligning Asset Management with Work Delivery
• Defining Continuous Improvement for Assets
• Interpreting the Asset Management Standards
• Engagement with Senior Management
Understanding the Organisation
• Working with Multiple Teams work to Deliver Asset Management
• Roles and Team Interfaces
• Results when Essential Functions are Missing
• Applying Policy and Strategy to People
Specifying Asset Management Strategy
• Defining the Asset Management Strategy
• Asset Management Objectives which are SMART
• Details of assets, their Design and Operational Requirements
• Applying Strategy
• Measuring the Performance of the Asset Management Strategy
Using Asset Management Plans
• Risk Management
• Measuring Risk in the Assets
• Asset Management Plan
• Forming Proposals of Work and Portfolio Management
• Avoiding Backlog in the Asset Management Plan
Condition Assessments, Life Cycle Costs and the Capital Plan
• Understanding Life Cycle Costs
• Requirements for Condition Assessments for Critical Assets
• Inspecting Assets and Adjusting Life Forecasts
• Generating the Capital Plan
• Technical Change Management
Feasibility Studies, Commissioning and Life Cycle Implications
• Specifications for the Pre-Feasibility Study
• Life Cycle Implications of the Feasibility Study
• Requirements for Manufacturing and Construction Quality
• Commissioning Assets
Operations, Maintenance and Reliability
• Life Cycle Management of In-Service Assets
• Avoiding Early Retirement and Unnecessary Waste
• Using Information Inform Asset Management Decision Making
• Tailoring Reliability Support for Decision Making
• Cultural implications of ISO 55000 s
Operations, Maintenance and Reliability
• Life Cycle Management of In-Service Assets
• Avoiding Early Retirement and Unnecessary Waste
• Using Information Inform Asset Management Decision Making
• Tailoring Reliability Support for Decision Making
• Cultural implications of ISO 55000 s
Continual Improvement in Asset Management
• Continuous Improvement
• Measuring Improvement over the Long Term
• Internal Auditing
• Performance Measurement
• Reporting to Senior Management
What you can expect to take away
1. Understand the policy and strategy framework which is appropriate for the organisation’s operations, budget and culture
2. Learn how to optimise forward budgets for capital, maintenance and engineering undertakings to optimise current asset performance
3. Understand the interfaces between different organisations within a company, and what happens when a key function is missing or not performing well
4. Using information to write the essential reports needed to optimize shutdowns, maintenance strategies, investment decisions and selection of external service providers
5. Self-reviewing the organisation with performance measures and internal audits to continually tune the management of assets by an integrated team of operations, maintenance, supply, projects and others
6. Relate the detail of ISO 55000 standards, PAS 55 and other local standards (e.g. government and enterprise asset management documentation) to delivering work related to assets;
7. Build an asset management plan which utilises condition data, reliability information, operational feedback and risk assessments to optimise capital investment and maintenance optimisation;
8. Improve the specification of roles of teams and confirm their areas of responsibilities;
9. Review the use of asset information and the systems managing this information
ASSET MANAGEMENT SCHOOL
so that practical improvements can be made to both system and its utilisation;
10. Set out a systematic specification of the life cycle processes for proposing and commissioning new assets, operations and maintenance, and the renewal of deteriorated assets to allow a self-review of gaps in the organisation’s approach; and 11. Specify an internal audit and performance measurement approach that will allow internal teams to identify and then focus on efficiency and productivity improvements
Asset Management Fundamentals
Cost and effective risk management of an organisation’s physical assets is a major opportunity for it to improve its sustainability and long-term productivity. Asset management has moved out from a technical function to an essential business management process. Global leaders have combined over many years to generate international standards and guidelines on best practice which are now having a significant effect in lifting asset management performance across all asset-intensive industries. Hence, executive leaders and senior managers benefit from familiarisation with the concepts and practices that their teams are now implementing.
This short course describes how an effective asset management system allows an organisation to best utilise its physical asset portfolio to achieve its business objectives. It describes expectations that the organisation’s teams must meet including risk-prioritised planning, quality management of asset life cycle process and requirements for continual improvement. Importantly, it identifies the strategic functions and systems in which the organisation must invest to realise its required operational outcomes.
5 Core Modules
• Overview of Asset Management
• Understanding Strategic Asset Management
• Expectations of Asset Management Teams
• Principles for Leading Asset Management
• Monitoring Asset Management Performance
Course outline
Overview of Asset Management
• Why Asset Management has Become Globally Important
• The Asset Management System and its Elements
• ISO 55000 Standards and Improving Asset Management
• Global Guidance on Asset Management Practices
Understanding Strategic Asset Management
• Purpose of Asset Management Policy and Strategic Asset Management Plan (SAMP)
• Investment in Managing Assets to meet Corporate Objectives
• Risk Management in Asset Planning
• Quality Assurance and Delivery of Work
Expectations of Asset Management Teams
• Delivery of Asset Management Process by Teams
• Measuring Performance
• Assessing the Health of the Asset Management System
• Modern Challenges for the Asset Management Teams
Summary
• Principles for Leading Asset Management
• Monitoring Asset Management Performance
• Other Information Resources
• Understand the policy and strategy framework which is appropriate for the organisation’s operations, budget and culture
• Learn how to optimise forward budgets for capital, maintenance and engineering undertakings to optimise current asset performance
• Understand the interfaces between different organisations within a company, and what happens when a key function is missing or not performing well
What you can expect to take away
1. Make the case for effective improvement in asset management.
2. Brief the team on elements of the globally defined and accepted asset management landscape essential for their organisation.
3. Specify the investments required in systems, competency, and processes to ensure successful delivery of asset management across the organisation.
4. Explain expectations that the team must have and what needs to be delivered and then reported up to have confidence that asset management is being delivered as per strategic requirements.
Shutdown School
Designed to assist maintainers, operators, supply officers, engineers and managers understand work associated with the delivery of shutdowns and turnarounds.
8 Core Modules
• Establishing The Shutdown
• Develop The Shutdown Organisation
• Shutdown Control Protocols
• Preparation
• Detailed Work Planning
• Scheduling
• Delivering Work
• Close-Out Of Shutdown
15 hrs over 2 days
15 hrs over 2 days
Course outline
Establishing The Shutdown
• Asset Management Plan – Shutdowns (Portfolio)
• Shutdown Initiation
• Establish the Steering Committee
• Appoint the Shutdown Manager
• Review the Shutdown Drivers
• Review Past Shutdowns (Continuous Improvement)
• Establish Shutdown Objectives
• Formulate Preparation Plan
Develop The Shutdown Organisation
• Planning and Scheduling Team
• Projects Management
• Works Delivery Team
• Logistics Team
• Materials Team
• Safety Management
• Technical Engineering and QA
• Production / Operations Management
Shutdown Control Protocols
• Establish Information Systems Strategy
• Establish Control Documents
• Establish Communication Plan
• Establish Registers
• Establish Document Management System
• Auditing Framework (Progress Monitoring)
Preparation
• Kick Off Meeting
• Generate the Scope of Work
• Approved Capital Project Work Orders
• Corrective and Proactive Work Orders
• Non – Running Preventive Maintenance Work
• Provisional Scope of Work
• Provisional Scope of Work Budget Estimate
Detailed Work Planning
• Categorise Work
• Plan Internal Resources Work
• Contractor Planned Package Work
Scheduling
• Work Integration Analysis
• Header Level
• Long Lead Procurement
• Pre-Shutdown Work
• Contracting
• Run Down / Run Up
• Isolations Planning
Delivering Work
• Work Pack Issue
• Isolations Management
• Work Pack Return
• Adjust Shutdown Schedule
• Shutdown Timetable Change
• Emergent Work
• Track Shutdown Progress
• Daily Meeting Schedule
• Commissioning
Close-Out Of Shutdown
• Shutdown Close-out Program
• Finalise Commercial Arrangements
• Finalise Technical Data
• Specification of Further Work
• Documentation
• Post-shut Review
What you can expect to take away
1. Implementation of a detailed shutdown process that is managed as a standard consistently taken up by all departments;
2. Specification of roles and responsibilities for executing the activities defined in the shutdown process, including the roles to manage, plan, schedule, and execute shutdowns and the personnel capability required for these roles;
3. Specification of the operational mechanisms (meeting schedules, format, objectives, and timing) needed to drive the process flow and interactions;
4. Explanation of the governance process and rules to make sure shutdown process is effective and efficient; and
5. Performance metrics and efficient control mechanisms to monitor shutdown effectiveness
MRO School
Bringing maintenance and supply chain practitioners together. While maintenance is focused on reducing risk, supply chain practitioners are goaled at lowering costs. These world views are hard to reconcile and cause friction. This course gets cross functional teams to think and act beyond their silo. It covers both the strategic focus providing context for ‘why’ as well as the tactical or operational focus teaching the ‘how to.’
7 Core Modules
• Begin With The END In Mind! What Good Looks Like – MRO Supply Chain
• What Gets Measured, Gets Improved!
• Master Data
• Warehouse Operations
• Inventory Management
• Purchasing
• Procurement Overview
Onsite
15 hrs over 2 days
15 hrs over 2 days
Course outline
Begin with the END in Mind! What good looks like – MRO Supply Chain
• Demand signal quality
• Catalogued materials usage vs Free Text
• High stock accuracy
• High stock turns
• Good relationship and control of vendors
• Strong control via KPI’s and Metrics
• Master Data is core
What gets measured, gets improved!
Supply Chain Effectiveness %
• Demand Signal Quality %
• Catalogued Material Spend %
• Stock Accuracy %
• Stock Turns %
• PO Automation %
Master Data
Material Master Data
• Lead Times
• ROP & ROQ
• Segmentation capability (MRP Controller)
EAM Master Data
• Structures like Functional Locations & Equipment
• BoM’s
Purchasing Master Data
• Vendor specific data (part numbers, lead time, price)
1. The identification and resourcing of master data objects
2. Clarity on the impacts (risk and cost) of catalogued material spend vs free text spend.
3. Impacts on your business from physical materials management – visibility and availability focused.
4. Catalogued Materials
• Free Text Materials
• Squirrel Stores
• Workplace Stores
• Tool Stores
5. How to eliminate duplicates materials within your operations (pure waste)
6. Learn about the difference between a MIN/MAX strategy vs ROP/ROQ strategy.
7. Learn how to manage potentially obsolete materials in conjunction with the Finance Team.
8. Clear understanding of how MRO materials are stocked to reduce risk reduction and the supply chain’s job is to do that at the lowest possible cost.
Precision Maintenance School
This intensive two-day interactive workshop is intended to prepare plant technicians, engineers and managers to take dead aim at Precision Maintenance (Fasteners, Lubrication, Alignment and Balance) in the plant and significantly improve the operational reliability of plant equipment and the plant processes they serve. The course also equips them with instructions to properly design, justify and implement a Precision Maintenance initiative.
9 Core Modules
• The Business Case For Precision Maintenance Management
• Taking A Microscope Look At Precision Maintenance Fundamentals
– An Introduction
• The Physics Of Machine Failure
• Modern, Machine Condition Monitoring – A Must For Precision Maintenance Management
• Reliability Engineering Methods For Precision Maintenance Management
• Fasteners
• Lubrication
• Alignment
• Balance
15 hrs over 2 days
15 hrs over 2 days
Course outline
The Business Case For Precision Maintenance Management
• Macro and microeconomic benefits for your organization
• Your journey to world-class, proactive maintenance
Taking A Microscope Look At Precision Maintenance Fundamentals –An Introduction
• Fastening to reduce mechanical vibration
• Lubrication to cushion the effects of mechanical vibration
• Alignment to reduce mechanical vibration
• Balance to reduce mechanical vibration
• How managing Precision Maintenance to reduce vibration and improve lubrication extends machine life
• Electrical applications of Precision Maintenance management
The Physics Of Machine Failure
• Failure mechanisms connect failure modes to failure causes
• Right design and operation to manage stress-strength interference
• Understanding mechanical failure modes and mechanisms
• Understanding electrical failure modes and mechanisms
Modern, Machine Condition Monitoring –A Must For Precision Maintenance Management
• Proactive versus predictive condition monitoring and condition-based maintenance
• Vibration analysis fundamentals
• Lubricant analysis fundamentals
• Thermographic analysis fundamentals
• Ultrasonic acoustic emissions fundamentals
• Motor evaluation fundamentals
• Non-destructive testing techniques
• The “eyeometer” – visual and sensory inspections should create your foundation
• Designing a machine condition monitoring program
• The P-F interval for determining how and how often to monitor machine health
• How condition monitoring drives down maintenance costs
• How condition monitoring drives down maintenance inventories
Reliability Engineering Methods For Precision Maintenance Management
• The basics of reliability engineering
• How to manage risk over the life cycle of equipment assets
Fasteners
• Bolting theory – how fasteners really work to hold machines together
• The difference between tension and torque
• How much tension? – Hooke’s Law
• How friction and lubrication influence torque and tension
• Proper bolting sequence
• Bolt basics – grades, standards and strength
• Wrong and right choices for washers
• Torque wrenches – 101
Lubrication
• Lubrication basics – the many roles of a lubricant
• Lubrication basics – the anatomy of a lubricant – it’s a bundle of performance properties
• How a lubricant protects the machine under full film, mixed film and boundary contact conditions
• Extending machine life with contamination control
• Machine set-up for lubrication maintainability
• Grease – not too much, not too little, but just right and just at the right time!
• Precision greasing with ultrasonic tools
Alignment
• The consequences of angular and offset misalignment
• How misalignment influences bearing life
• How misalignment influences coupling life
• How to detect misalignment with vibration analysis
• Laser alignment
• Managing pipe strain with alignment
Balance
• The basics of balancing
• Causes of imbalance
• How imbalance induced relative centrifugal force (RCF) robs your machines of life
• Balancing standards – ISO and API
• Single plane field balancing
What you can expect to take away
1. How Precision Maintenance management drives bottom line performance
2. Precision Maintenance management at work and the physics mechanical and electrical machine failure
3. Practical machine condition monitoring applications – with a special focus on proactive condition-based maintenance
4. How to leverage reliability engineering practices to improve Precision Maintenance management
5. How to practically apply Fastener, Lubrication, Alignment and Balance practices in the plant to drive reliability
6. How to manage the planning, scheduling and work management to assure effective Precision Maintenance management
7. How to cost justify your Precision Maintenance management initiative – and sell it to management
8. Best practices for assessing your strengths, weaknesses, opportunities and threats in Precision Maintenance management so you can take a targeted approach at addressing your weaknesses
9. Recap – summary of Precision Maintenance management best practices
In addition to the course and a complete course book, you’ll leave with a copy of Sigma Reliability’s proprietary Precision Maintenance management SWOT analysis tool and an extensive library of documents, calculators, applicable standard and other resources so you don’t have to reinvent the wheel in your journey toward excellence and managing Precision Maintenance in your plant and organisation.
Sustainable Assets School
Decarbonisation and the need for companies to achieve net-zero greenhouse gas emissions by a specified date is disrupting previous lifecycle plans, investment and reinvestment decisions, and the physical asset manager’s role. This course is designed for Asset Managers to explore best practices in energy consumption reduction, including reducing GHG emissions, managing energy conversion effectiveness and transfer along its intended electrical, mechanical, and chemical pathways, and reducing wear and tear on production.
11 Core Modules
• Introduction To ESG And Sustainable Manufacturing
• Energy Savings And GHG Reduction Potential
• Energy Efficiency Of Industrial Electric Motors And The Machines They Drive
• Diesel Engine Combustion Efficiency
• Pumping System Efficiency
• Compressed Air Energy Efficiency
• Process Heating Energy Efficiency
• Steam System Energy Efficiency
• Buildings And Lighting
• Electrical Transformers
• Implementing Industrial Energy Management Best Practices
15 hrs over 2 days
15 hrs over 2 days
Course outline
Introduction to ESG and Sustainable Manufacturing
• Environmental, Societal and Governance (ESG) Goals and Trends
• The “Triple Bottom Line”
• Introduction to Environmental Life Cycle Assessment (ELCA)
• Mapping Impacts and Setting Priorities
• Choosing Key Performance Indicators (KPIs) for Sustainable Manufacturing
– Inputs
– Operations
– Products Including Production Assets
• Sustainable Life Cycle Asset Management Practices
• Design
• Operations
• Maintenance
• Life Extension, Recycle/Reuse
• Asset Managers Role in Sustainability
Energy Savings and GHG Reduction Potential
• Energy vs Exergy Explained
• Common Energy Losses
• Parasitic Frictional Losses
• Adiabatic Losses
• Emissions Losses
• Intentional
– Venting of Compressed or Pressurized Fluids
– Flaring
• Unintentional Fugitive Emissions
– Compressed Air and Gases
– Pressurized Steam
– Pressurized Liquids
– Compressed Natural Gas and Other VOCs
• Radiant Energy
• Combustion Efficiency
• Recovery Opportunities
• Reduced Energy Cost
• Reduced Greenhouse Gas (GHG) Emissions and Carbon Footprint
• Energy Savings Opportunities for Industry:
– By Deploying Existing Technology
– With Investment in New Technology
Energy Efficiency of Industrial Electric Motors and the Machines They Drive
• When to Purchase Premium Efficiency Motors
• How to Estimate Motor Efficiency in the Field
• Strategies to Extend the Operating Life of Electric Motors
• The Importance of Motor Shaft Alignment
• When to Replace V-belts with Synchronized Belts
• How to Avoid Nuisance Trips with Premium Efficiency Motors
• How to Eliminate Voltage Unbalance
• Strategies to Eliminate In-Plant Distribution System Voltage Drops
• How to Improve Motor Operation at Off-Design Voltages
• When It Makes Sense to Turn Motors Off
• How to Improve Efficiency of Adjustable Speed Drives Operating at Partial Load
• Is it Cost-Effective to Replace Old Eddy-Current Drives?
• Magnetically Coupled Adjustable Speed Drives
• When Should Inverter-Duty Motors be Specified?
• Minimize Adverse Motor and Adjustable Speed Drive Interactions
Diesel Engine Combustion Efficiency
• Regular Maintenance
• Fuel Quality Management
• Fuel Injection System Optimization
• Combustion Chamber Optimization
• Turbocharging
• Exhaust Gas Recirculation (EGR)
• Air Intake System Optimization
• Engine Control Unit Calibration
• Idle Reduction
• Driver Training
• Aerodynamic Improvements
• Payload Optimization
Pumping System Efficiency
• Conduct an In-plant Pumping System Survey
• Match Pumps to System Requirements
• Adjustable Speed Pumping Applications
• Control Strategies for Centrifugal Pumps with Variable Flow Rate Requirements
• Energy Savings Opportunities in Control Valves
• Reduce Pumping Costs Through Optimum Pipe Sizing
• Optimize Parallel Pumping Systems
• Pump Selection Considerations
• Select and Energy Efficient Centrifugal Pump
• Trim or Replace Impellers on Oversized Pumps
• Test for System Efficiency
• Maintain Pumping Systems Effectively
Compressed Air Energy Efficiency
• How to Analyse Compressed Air Systems
• Alternative Strategies for Low Pressure End Uses
• Strategies for Storing Compressed Air Systems
• Strategies for Energy Efficient Compressed Air Systems
• How to Determine the Cost of Compressed Air in Your Plant
• How to Determine the Correct Air Quality for the Application
• Effective Management of Air Intake Systems
• Eliminating Inappropriate Application and Uses of Compressed Air
• Engineering End Uses for Maximum Efficiency
• Maintaining Compressed Air Quality
• Finding and Eliminating Compressed Air Leaks
• Proactive, Predictive and Precision Maintenance for Compressed Air Systems
• How to Minimize Air Losses When Removing Condensate
• How to Stabilize System Pressure
• Capturing and Reusing Adiabatic Losses
Process Heating Energy Efficiency
• Maintaining Proper Fuel to Air Ratios
• How to Check Heat Transfer Surfaces
• Managing Furnace Pressure Controllers
• Installing Waste Heat Recovery Systems
• Load Preheating Using Flue Gases for a Fuel Fired Heating System
• How to Oxygen-Enrich Combustion
• Preheated Combustion Air
• Reducing Air Infiltration in Furnaces
• Minimizing Radiant Energy Losses from Heating Equipment
• Using Lower Flammable Limit Monitoring to Improve Efficiency
• Reclaiming Waste Heat for External Processes
Steam System Energy Efficiency
• How to Benchmark the Fuel Cost of Steam Generation
• How to Clean Boiler Waterside Heat Transfer Surfaces
• When to Install and Condensing Economizer
• When to Install High-Pressure Boiler with Backpressure Turbine Generators
• When to Install Turbulators on Two – and Three-Pass Firetube Boilers
• When Does It Make Sense to Drive Rotating Equipment with Steam Turbines?
• What to Consider When Selecting a Condensing Economizer
• Coving Heated, Open Vessels
• Employing Deaerators in Industrial Steam Systems
• How to Flash High-Pressure Condensate to Regenerate Low-Pressure Steam
• How to Inspect and Repair Steam Traps
• Installing an Automatic Blowdown-Control System
• Installing Removable Insulation on Valves and Fittings
• How to Insulate Steam Distribution and Condensate Return Lines
• How to Improve Combustion Efficiency in Boilers
• How to Minimize Boiler Blowdown
• Minimizing Boiler Short-Cycling Losses
• Heat Recovery from Boiler Blowdown
• Replacing Pressure-Reducing Valves with Backpressure Turbogenerators
• Effective Return of Condensate to the Boiler
• Upgrading Boilers with Energy-Efficient Burners
• Using Feedwater Economizers for Waste Heat Recovery
• Using Low-Grade Waste Steam to Power Absorption Chillers
• Employing Steam Jet Ejectors to Reduce Low-Pressure Venting
• Employing Vapor Recompression to Recover Low-Pressure Waste Steam
• Using a Vent Condenser to Recover Flash Steam Energy
Buildings And Lighting
• Reducing Energy Consumption with Intelligent Industrial Buildings
• Upgrading Industrial Lighting with Energy Efficient Technologies
• Utilizing Drones Equipment with IR Cameras to Identify Fugitive Energy Emissions from Industrial Buildings
Electrical Transformers
• How to Control I2R Copper Losses
• Minimizing Hysteresis and Eddy Current Losses (Iron Losses)
• Managing Stray Current Losses Induced by Magnetic Fields
• How Winding Resistance and Leakage Flux Produce Load Losses
• Minimizing Hysteresis and Eddy Current Losses Under No-Load Conditions
• Addressing Leakage Flux
• Managing Insulating Materials to Minimize Dielectric Losses
• Maintaining Energy Efficiency of Transformer Cooling Systems
• Employing Active and Passive Filters to Minimize Harmonic-Induced Losses
• Assuring Proper Frequency Selection for the Application
• How to Keep Overloading Losses to a Minimum
Implementing Industrial Energy Management Best Practices
• How to Set Energy Management Goals for Industrial Assets
• How to Conduct and Energy Audit for Industrial Assets
• How to Develop and Energy Management Plan for Industrial Assets
• Energy Monitoring and Metering for Industrial Assets
• Training and Engaging Employees in the Process
• How to Implement Your Plan to Improve Industrial Energy Efficiency
• Continuous Monitoring, Auditing, and Improvement
• Seeking Recognition and Certification for Your Organization
What you can expect to take away
1. Understand Why Environmental Sustainability is a Burning Platform for Most Organisations
2. Learn that Improving Profit and Decarbonization aren’t Conflicting Goals
3. Understand How Sustainable Energy Management Drives Safety
4. Know How to Define Your Carbon Footprint Reduction
5. Implement procedures for Managing Parasitic Mechanical Frictional Losses
6. Gain Insights About How to Minimize Intentional and Fugitive Emissions of Pressurized Fluids
7. Understand How to Improve Combustion Efficiency in Engines, Process Heating, and Steam Systems
8. Minimize Electrical Resistance Energy Losses
9. Learn Techniques for Minimizing Destructive Electrical Harmonics
10. How to Minimize Phase-to-Phase Electrical Unbalance
11. Create Standards to Design, Operate, Maintain, and Reuse/Recycle for Lifecycle Sustainability
12. Execute Energy Management Practices that Improve Profits and Reduce Carbon Footprint
LEVEL 1
Lubrication School
Provides the foundational skillset for applying best lubrication practices and product knowledge. You’ll learn proven industry methods for selecting, storing, filtering and testing lubricants to boost reliability and generate lasting results in machine efficiency/maintenance, plus a better understanding of oil analysis.
20 Core Modules
• How Lubrication Affects Machine Reliability
• Lubrication Fundamentals
• Understanding Additives, Base Oils And Grease Thickeners
• Lubricant Performance Properties
• Lubricating Grease Application Methods
• Lubricating Oil Application Methods
• Journal Bearing Lubricants
• Rolling-Element Bearing Lubricants
• Gear Lubricants
• Automotive And Mobile Equipment Drive-Line Lubricants
• Compressor Lubricants
• Steam And Gas Turbine Lubricants
• Hydraulic Fluids
• Contamination Control
• Oil Drains, Flushing And Reservoir Management
• Storing, Handling And Managing Lubricants
• Design And Inspect For Lube Excellence
• Lubricant Failure
• Used Oil Sampling And Analysis Fundamentals
• Essential Field Inspections
• Lubrication Selection And Consolidation 22
What Our Clients Say
“Asset Schools give peace of mind that the investment in our Maintenance and Reliability professionals will provide a great return to both them and the business. ”
Gwyn Garland
Global Head of Plant
Anglo American
“ The training provided by Asset Schools was exceptional, offering a highly educational experience that enabled us to learn a wealth of new knowledge and skills. ”
Ali Sahin
Senior Engineer, Reliability
Rio Tinto
“Asset Management School was absolutely fantastic! Not just the content, but also the networking evening, the whole experience. Despite 23 years as a maintenance engineer and planner, I learnt so much to take back to apply in my business. ”
Salman Rashed
Asset Maintenance Planner
Waikato Regional Council
“ The knowledge and practical steps imparted during Asset Schools have proven to be invaluable for the overall improvement across the business in greater availability and reduced unit lifecycle costs. Attendance at the Asset Schools portfolio of courses is now a foundation requirement for our team of planners due to the business and personal development benefits.”
Ash Davis
OAM,
Senior Mines Systems Planner Fortescue
“Asset Management School is a great investment for experienced Maintenance Practitioners who want to fine tune their skills, or for new entrants to use it as a sound starting base to the industry. ”
Roh Perera Planning Supervisor Macmahon
Course outline
How Lubrication Affects Machine Reliability
• Financial benefits from achieving lubrication excellence
• Four equipment maintenance strategies and when each applies
Lubrication Fundamentals
• Six important functions of lubricating oils
• How oils and greases are formulated and why it is important
• How friction is generated in lubricated machinery
• The importance of oil film thickness and critical clearances
Understanding Additives, Base Oils And Grease Thickeners
• How lubricant properties irreparably change
• Seven important physical properties of a base oil
• The importance of API’s five base oil categories
• What causes grease to dry out and 18 ways to prevent it
• How to detect the root causes of lubricant oxidation
• When to select 1 of the 6 most used synthetic base oils
• How to use temperature to determine the right base oil for your machine
• How to select grease thickeners for your application
Lubricant Performance Properties
• Key additives that enhance lubricant performance
• Viscosity grades, measurement and reporting
• Why Viscosity Index is important
• Oil viscosity changes and how to set monitoring limits
• Lubricant performance tests & reporting
• How water contamination generates other contaminants
• How to control and eliminate aeration problems
Lubricating Grease Application Methods
• How to protect against incompatible grease mixtures
• Advantages/disadvantages of centralized lubrication systems
• Best practices for greasing motor bearings
• How to control pressure when greasing bearings
• The unique problems caused by over greasing
• 3 critical instructions to give your electric motor rebuild shop
• Comparing single – and multi-point lubrication options
• How to calculate greasing intervals/quantity
• Best practices for ultrasonic/sonic-based greasing
Lubricating Oil Application Methods
• Overview of oil lubrication methods/devices
• How to use oil mist and other automatic lubrication methods
• Using pressure spray methods for gearboxes
• Best practices for the maintenance of grease guns and fittings
• Protect against problems caused by constant-level oilers
• Overview of single-point direct lubrication systems
Journal Bearing Lubricants
• The eight most common journal bearing lubrication problems
• How to select journal bearing viscosity based on speed
Rolling-Element Bearing Lubricants
• Nine factors affecting rolling-element bearing lubricant selection
• How to convert required operating temperature viscosity to ISO viscosity
Gear Lubricants
• Five key requirements for gear oil
• How to select the best viscosity for a gear lubricant
• Best practice guidelines for storing spare gearboxes
• 10 conditions that may require synthetic gear lubricants
• Lubrication best practices for enclosed gears – a 12-point checklist
• Mastering the challenges of open gear lubrication
Automotive And Mobile Equipment Drive-Line Lubricants
• How to read a motor oil label: what matters
• The six critical objectives a motor oil must accomplish
• Understanding API service classifications for engine and gear oils
• Service classifications for automotive greases – how to select
• Extending engine life – surprising engine oil filter study results
Compressor Lubricants
• Steps you can take right now to combat compressor lubricant failure
• The most common compressor lubricant stressors
• When to use synthetic compressor lubricants and why
Steam And Gas Turbine Lubricants
• Why turbine/generator lubricants are the No. 1 contributor to forced outages
• Comparing steam and gas turbine oils – how they differ
• Checklist for best-practice steam turbine lubrication
Hydraulic Fluids
• How to select the ideal hydraulic fluid viscosity for gear, vane and piston pumps
• Nine key hydraulic fluid requirements and why they matter
• Specific conditions that may require a synthetic hydraulic fluid
• Fire-resistant hydraulic fluids
• Hydraulic system maintenance best practices
Contamination Control
• Strategies for building reliability through contamination control
• The seven most destructive contaminants and how to control them
• Specific steps for managing a proactive lubricant maintenance program
• The ISO solid contaminant code – understand it, track it
• 10 ways to get more mileage out of portable filter carts
• How dirt, metal particles and soot mechanically destroy machine surfaces
• Guidelines for controlling machine surface fatigue and extending machine life
• The No. 1 cause of machine wear and how to manage it
• How to set realistic cleanliness levels for lubricants
• Effective lubricant contamination control strategies for extending machine life
• 4 ways water contamination attacks lubricant additives
• How to set limits for watering-oil contamination
• Managing the root causes of foam and aeration
• Best practices for excluding and removing contaminants
• The right way to control contamination in tanks and sumps
• How oil filters are rated
• Best practices for removing water contamination from oil
• The unique problems created by varnish
Oil Drains, Flushing And Reservoir Management
• How to optimize and extend oil change intervals
• Interval vs. condition-based oil changes – pros and cons
• Metrics for monitoring lubricant consumption
• Best practices for oil changes
• Know how and when to perform a flush
• The best procedures for oil draining and refilling
• How and when to use the bleed-and-feed strategy for extending oil drains
• Selecting the right cleaning and flushing procedures
Storing, Handling And Managing Lubricants
• How to set up a world-class lube room
• How to know when to reject a new oil delivery
• Implement a lubricant consolidation program and select suppliers
• Used lubricant storage, handling and disposal best practices
• Bulk lubricant storage do’s and don’ts
• Guidelines for storing and handling drums
• Lubricant dispensing options and what you must avoid
• Lubricant coding and identification systems – what works and what doesn’t
• Portable oil transfer and filter carts selection advice
• How and where to store oil transfer and filter carts
• Understanding and managing lubricant storage life
• Keeping grease fresh – best practices for storage
Design And Inspect For Lube Excellence
• Accessorizing equipment for lubrication excellence
• Seven critical accessories for lubricant inspection and sampling
• The right machine accessories for effective contamination control
Lubricant Failure
• Know the factors that contribute to lubricant failure
• Thermal and oxidation processes and their effects on lubricants and additives
• Common wear mechanisms caused by debris
• Recognize what causes lubricant degradation
• Recognizing the by-products of lubricant failure and wear debris
• Distinguishing the specific test that measures the forms of lubricant degradation and wear debris monitoring
• Interpret data to set alarms and limits based upon test results
Used Oil Sampling And Analysis Fundamentals
• Types and categories of oil analysis
• Applications for oil analysis
• Overview of oil analysis tests
• Elements of a successful oil analysis program
• How clean should oil sample bottles be?
• How to find the best sampling locations
• Oil sampling valve and hardware recommendations
• A quick method for optimizing sampling intervals
• An oil sampling technique that ruins trending
• The importance of primary and secondary sampling points
• Advice for sampling hard-to-reach machines
• How to properly sample circulating systems
• Safe, effective high-pressure sampling from hydraulic systems
Essential Field Inspections
• 12 questions your oil filter will answer about your machine
• Visual inspections you can get big results from right now
• Quick tips for using scent, sound and touch to inspect lubricants
Certification
Certification with ICML
Upon course completion, you are eligible to get certified through the International Council for Machinery Lubrication (ICML). Please note the certification process is to be booked and paid for directly through the ICML and is not part of the course. Visit https://www.icmlonline.com/.
Why Certify?
Certification is an important part of the training process because it confirms you possess the skills to do the job. Combining training with certification creates a knowledgeable and valuable employee.
Which Certifications?
Lubrication School Level 1 is designed to help you prepare for Level I Machine Lubrication Technician (MLT I) OR Level I Machine Lubricant Analyst (MLA I) ICML Certification Exams. https://www.icmlonline.com/
What Is ICML?
The International Council for Machinery Lubrication (ICML) is a vendor-neutral, notfor-profit organization founded to facilitate the growth and development of machine lubrication as a technical field of endeavour.
Lubrication School
LEVEL 2
Advanced training in lubrication excellence. Covers advanced lubrication topics like lubricant selection, troubleshooting, predictive maintenance and more. Designed for maintenance professionals with a solid understanding of the benefits and potential in excellent lubrication practices.
15 Core Modules
• Lubrication PM Optimisation And Design
• Troubleshooting Lubrication Problems
• Lubrication And Oil Analysis Metrics
• Oil Drains, Flushing And Reservoir Management
• Accessorizing New Equipment For Lubrication Excellence
• Lubricating Grease Application
• Lubricant Application
• Lubrication Fundamentals
• Base Oils
• Viscosity And Viscosity Index
• Oxidation And Thermal Stability
• Air Release And Foam Control
• Lubricant Degradation
• Leakage Stability
• Lubrication Selection And Consolidation
22 hrs over 2.5 days
22 hrs over 2.5 days
22 hrs self-paced
Course outline
Lubrication PM Optimisation And Design
• Five questions to ask about every lubrication PM
• How to rationalize and modernize your lubrication PMs
• What causes grease dry-out and when it should be refreshed
Troubleshooting Lubrication Problems
• How to troubleshoot lubrication problems effectively
• Four troubleshooting data – collection guidelines
• How to recognize wear patterns on gear teeth
• 28 tips for preventing gear failures
• How to effectively troubleshoot bearing failures
Lubrication and Oil Analysis Metrics
• Four metrics for measuring lubrication effectiveness
• How to track costs and savings
• Measuring the impact of lubrication excellence on RONA
Oil Drains, Flushing and Reservoir Management
• 10 ways to ensure sump lubricant health
• How to optimize interval-based oil changes
• Strategies for condition-based oil changes
• How to use a bleed-and-feed strategy for extending oil drains
• How to trend oil consumption ratios
• Best practices for oil draining and refilling
• Checklist of important machine accessories for inspections and sampling
• Seven strategic machine accessories for contamination control
Accessorizing New Equipment for Lubrication Excellence
• Checklist of important machine accessories for inspections and sampling
• 7 strategic machine accessories for contamination control
Lubricating Grease Application
• What to do before and after installing an electric motor
• How to calculate ideal relubrication volume for electric motors
• How to optimize bearing regreasing intervals
• Strategy for ultrasonic/ sonic-based regreasing volume
• How to determine bearing grease fill levels
Lubricant Application
• 7 important guidelines for lubricating plain bearings
• Considerations for proper worm gear lubrication
• Best practices for selecting and applying open gear lubricants
• Relubrication frequency recommendations for gear and grid couplings
• 14 best practices for steam turbine lubrication
• Best practices for process pump lubrication
• Best practices for lubricating compressors
Lubrication Fundamentals
• Factors that influence hydrodynamic lubrication
• Five things that can change oil film thickness
• How gear speed influences lubrication
• Seven lubrication factors for finding the “sweet spot” for energy consumption
Base Oils
• API base oil groups and why they are important
• How synthetic base oil properties compare
• Strengths, weaknesses and applications for six synthetic base oils
• Compatibility of eight seal materials with different fluid types
Viscosity and Viscosity Index
• Understanding the viscosity/temperature chart
• Cold-temperature motor oil viscosity basics
• How oil aging affects oil viscosity
• How slight errors in viscosity selection can result in wear and energy losses
• How to convert required operating temperature viscosity to ISO viscosity grades
Oxidation and Thermal Stability
• How antioxidants alter oil life
• How oxidation stability is measured and why it’s important
• Why varnish, sludge and deposits are a problem
• The typical sequence of events leading to varnish
Air Release and Foam Control
• Causes of poor air release and foaming in oil
• How to know when oil foam is a problem and how to troubleshoot
• Strategies for controlling aeration and foam
Lubricant Degradation
• How to detect mixed lubricants
• Five ways lubricants degrade irreparably
• Nine ways additives are rendered useless
• Lubricant shelf life – factors to control
Leakage Stability
• How fluid properties affect seal performance
• How to use dye for efficient leak detection
• Pros and cons of quick stop leak agents
Lubrication Selection and Consolidation
• The Seven critical factors when selecting grease
• Properties of grease that affect pumpability
• How service temperature affects different grease types
• How grease properties change due to incompatible mixtures
• Importance of grease properties by application
• Eight critical factors for selecting a lubricant
• Basic and advanced approaches for consolidating lubricants
• Matching lubricants to machines based on robustness, price and usage
• Managing the lubricant vendor service and delivery quality
• How new lubricant quality can be compromised
• How to read an oil can
• How to determine when to select a monograde vs. a multigrade oil
• Using bearing speed factors to determine NLGI numbers
• Selection criteria for electric motor grease
• 10 desired properties for refrigeration lubricants
• Five requirements for gear oils and why they are important
• How to decide when synthetic gear lubes are required
• Three methods for selecting gear oil viscosity
• Conditions when synthetic hydraulic fluids may be required
• How to select the correct hydraulic fluid viscosity
• How the hydraulic fluid selection process can save money
• Four important characteristics every chain lubricant should have
What you can expect to take away
1. Uncover the secrets of lubricant selection and understand the importance of lubricant properties and strategies for selecting the correct lubricant for each machine application
2. Obtain effective oil analysis with precision oil sampling and learn how to get data-rich oil samples, where to install oil sampling ports, and what sampling equipment should and shouldn’t be used
3. Understand the best practices for lubricant storage, handling and dispensing and how award-winning maintenance programs design lube storage areas, dispensing stations and transfer carts
4. Learn the four Rs of lubrication (right lubricant, right time, right quantity and right place) and the newest methods for implementing the best lubrication practices
5. Realize that grease gun can be a lethal weapon. In the hands of an untrained operator, a grease gun can deliver pressure up to 15,000 psi – 30 times what a
typical bearing seal can handle. This course will teach you proper grease gun practices
Certification with ICML
Upon course completion, you are eligible to get certified through the International Council for Machinery Lubrication (ICML). Please note the certification process is to be booked and paid for directly through the ICML and is not part of the course. Visit https://www.icmlonline.com/.
Why Certify?
Certification is an important part of the training process because it confirms you possess the skills to do the job. Combining training with certification creates a knowledgeable and valuable employee.
Which Certification?
Lubrication School Level 2 is designed to help you prepare for Level II Machine Lubrication Technician (MLT II) ICML certification exam. Visit https://www.icmlonline. com/
What Is ICML?
The International Council for Machinery Lubrication (ICML) is a vendor-neutral, notfor-profit organization founded to facilitate the growth and development of machine lubrication as a technical field of endeavour.
Lubrication Awareness
An overview of how lubricants work and many elements that are important to an effective lubrication program. Whether you’re a manager, engineer, technician or operator, this course is designed to show you the relevance of an effective lubrication program to your role, and how it contributes to reliability.
13 Core Modules
• Maintenance and Machine Reliability
• Tribology, Wear and Viscosity
• Base Oils and Additives
• Grease Fundamentals
• Lubricating Oil Application Methods
• Lubricating Great Application Methods
• Lubrication Application Electric Motors
• Particle Contamination
• Water Contamination
• Contamination Control
• Oil Drains, Flushing and Reservoir Management
• Lube Room, Handling, Storage and Management of Lubricants
• Field Inspections, Basic Machine Care and Daily Rounds
• Lubricant Degradation
• Leakage Stability
• Lubrication Selection And Consolidation
4 hrs over 1 day
4 hrs over 1 day
3 hrs self-paced
Lubrication Fundamentals
A foundational understanding of lubrication enabled reliability. The fundamentals of machinery lubrication necessary for a foundational understanding of lubrication enabled reliability. A basic review of the important functions of a lubricant will be covered, then the course will continue to demonstrate the impact of contamination on machine components.
11 Core Modules
• How Lubrication Affects Machine Reliability
• Lubrication Fundamentals
• Additives, Based Oils And Grease Thickeners
• Lubricant Performance Properties
• Grease Application Methods
• Oil Application Methods
• Contamination Control
• Oil Drains, Flushing, And Reservior Management
• Storing, Handling And Managing Lubricants
• Lubricant Failure
• Essential Field Inspections
8 hrs over 1 day
8 hrs over 1 day
Course outline
How Lubrication Affects Machine Reliability
• Financial benefits from achieving lubrication excellence
• 4 equipment maintenance strategies and when each applies
Lubrication Fundamentals
• Six important functions of lubricating oils
• How oils and greases are formulated and why it is important
• How friction is generated in lubricated machinery
• The importance of oil film thickness and critical clearances
Additives, Based Oils and Grease Thickeners
• How lubricant properties irreparably change
• Seven important physical properties of a base oil
• The importance of API’s five base oil categories
• What causes grease to dry out and 18 ways to prevent it
• How to detect the root causes of lubricant oxidation
• When to select 1 of the 6 most used synthetic base oils
• How to use temperature to determine the right base oil for your machine
• How to select grease thickeners for your application
Lubricant Performance Properties
• Key additives that enhance lubricant performance
• Viscosity grades, measurement and reporting
• Why Viscosity Index is important
• Oil viscosity changes and how to set monitoring limits
• Lubricant performance tests & reporting
• How water contamination generates other contaminants
• How to control and eliminate aeration problems
Grease Application Methods
• How to protect against incompatible grease mixtures
• Best practices for the maintenance of grease guns and fittings
• Best practices for greasing motor bearings
• How to control pressure when greasing bearings
• The unique problems caused by over-greasing
• 3 critical instructions to give your electric motor rebuild shop
• Comparing single – and multi-point lubrication options
• Best practices for the maintenance of grease guns and fittings
• Best practices for ultrasonic/sonic-based greasing
Oil Application Methods
• Overview of oil lubrication methods/devices
• Protect against problems caused by constant-level oilers
• Overview of single-point direct lubrication systems Contamination Control
• Strategies for building reliability through contamination control
• The seven most destructive contaminants and how to control them
• Specific steps for managing a proactive lubricant maintenance program
• The ISO Solid Contaminant Code – understand and track it
• 10 ways to get more mileage out of portable filter carts
• How dirt, metal particles and soot mechanically destroy machine surfaces
• Guidelines for controlling machine surface fatigue and extending machine life
• The #1 cause of machine wear and how to manage it
• 4 ways water contamination attacks lubricant additives
• Managing the root causes of foam and aeration
• Best practices for excluding and removing contaminants
• How oil filters are rated
• Best practices for water contamination from oil
• The unique problems created by varnish
Oil Drains, Flushing, and Reservior Management
• How to optimize and extend oil change intervals
• Interval vs. condition-based oil changes – pros and cons
• Best practices for oil changes
• Know how and when to perform a flush
• The best procedures for oil draining and refilling
Storing, Handling And Managing Lubricants
• How to set up a world-class lube room
• How to know when to reject a new oil delivery
• Used lubricant storage, handling, and disposal best practices
• Bulk lubricant storage do’s and don’ts
• Guidelines for storing and handling drums
• Lubricant dispensing options and what you must avoid
• Lubricant coding and identification systems – what works and what doesn’t
• Portable oil transfer and filter carts selection advice
• How and where to store oil transfer and filter carts
• Understanding and managing lubricant storage life
• Keeping grease fresh – best practices for storage
Lubricant Failure
• Know the factors which contribute to lubricant failure
• Thermal and oxidation process and its effects on lubricants and additives
• Identify common wear mechanism caused by debris
• Recognize what causes lubricant degradation
• Recognize the byproducts of lubricant failure and wear debris
Essential Field Inspections
• 12 questions your oil filter will answer about your machine
• Visual inspections you can get big results from right now
• Quick tips for using scent, sound, and touch to inspect lubricants
Vibration Analysis
LEVEL 1 : ENTRY
The ‘Entry’, or ‘Junior Level’ Mobius Institute™ Category I course is intended for personnel who are new or have 6 months vibration monitoring and analysis experience. The course focuses on periodic, single channel data collection and analysis for condition-based maintenance programmes. A foundation is established for in-depth understanding of spectrum and waveform relationships.
6 Core Modules
• Maintenance Practices
• Condition Monitoring
• Principles Of Vibration
• Data Acquisition
• Equipment Knowledge
• Basic Vibration Analysis
25 hrs over 3.5 days
25 hrs over 3.5 days
Course outline
Maintenance Practices
• Breakdown, preventive, predictive and RCM
Condition Monitoring
• Review of condition monitoring technologies: Vibration, oil, wear debris analysis, infrared thermography, ultrasonic acoustic emission, electric motor testing
Principles of Vibration
• Motion, r.m.s./peak/peak-peak, frequency/ period
• Displacement, velocity and acceleration
• Units and unit conversion
• Waveform and spectrum (FFT)
• Natural frequencies
• Basic forcing frequency calculations
Data acquisition
• Instrumentation
• Transducers and transducer mounting
• Measurement point naming conventions
• Routes/surveys: Loading and unloading the route
• Data collection
• Following a route
• Repeatable data collection
• Test procedures
• Observations: utilising your time effectively in the field
• Recognizing bad data
Equipment Knowledge
• Rotating equipment types and applications
• Rolling element bearings and journal bearings
• Review of failure modes and appropriate use of condition monitoring technologies
Basic Vibration Analysis
• Overall level measurements
• Spectrum analysis: Harmonics, sidebands and the analysis process
– Defects associated with bearings, gears, belts, electric motors
What you can expect to take away
You will come away from this course with a very good understanding of vibration analysis fundamentals, you will understand how to take good measurements, and you will be ready to begin analyzing vibration spectra.
Certification (optional)
At 11am on Day 4, there is an optional 2-hour exam with a 70% passing grade. The exam follows ISO 18436-2 and 18436-3 and provides 3 Continuing Education Unit (CEU) credits.
Registered students are given access to the online version of the course via the Mobius Institute Learning Zone™ before the class and for four months after course completion to assist them with converting the course information into practice.
No prior experience is required for attending the training course, but 6 months of experience is required for certification.
Vibration Analysis
LEVEL 2 : INTERMEDIATE
The VA Cat 2 may be suitable for those who either have: completed a VA Cat 1; a degree in Mechanical Engineering or; have significant vibration analysis experience, including an understanding of vibration theory and terminology. The course provides an in-depth study of machinery faults and their associated spectrum, time waveform and phase characteristics.
11 Core Modules
• Review Of Maintenance Practices
• Review Of Condition Monitoring Technologies
• Principles Of Vibration
• Data Acquisition
• Signal Processing
• Vibration Analysis
• Detailed Fault Analysis
• Equipment Testing And Diagnostics
• Corrective Action
• Successful Condition Monitoring Program
• Acceptance Testing And ISO Standard
35 hrs over 4.5 days
35 hrs over 4.5 days
Course outline
Review of Maintenance Practices
• Breakdown, preventive, predictive and RCM
Review of Condition Monitoring Technologies
• Vibration, oil, wear debris analysis, infrared thermography, ultrasonic acoustic emission, electric motor testing
Principles of Vibration
• Complete review of basics
• Waveform and spectrum (FFT), phase and orbits
• Understanding signals
Data Acquisition
• Transducers types, selection and mounting
• Measurement point selection
• Following routes, test planning, measurement errors
• Analysis of induction motors, gears, belts, pumps, compressors, and fans
• Lots of case studies and exercises for participants
Equipment Testing and Diagnostics
• Impact testing (bump tests)
• Phase analysis
Corrective Action
• General maintenance repair activities
• Review of the balancing and shaft alignment process
Successful Condition Monitoring Program
• Setting baselines and alarm limits
• Report generation, reporting success stories
Acceptance testing and ISO standard
What you can expect to take away
You will come away with a very good understanding of the fundamentals and you will feel comfortable analyzing vibration spectra, time waveforms, envelope data, and phase data.
Certification (optional)
At 1pm on Day 5, there is an optional 3-hour exam with a 70% passing grade.
The exam follows ISO 18436-2 and 18436-3 and provides 3.5 Continuing Education Unit (CEU) credits.
Registered students are given access to the online version of the course via the Mobius Institute Learning Zone™ before the class and for four months after course completion to assist them with converting the course information into practice.
No prior experience is required for attending the training course, but 18 months of experience is required for certification.
Vibration Analysis
LEVEL 3 : ADVANCED
For candidates who are committed to reliability through condition monitoring, and who have at least two years vibration analysis experience. It is ideal for those who lead a vibration team or take a pivotal role in diagnosing faults and making final recommendations. This course will give the analyst all of the skills and knowledge necessary to solve all fault conditions, run a successful condition monitoring program and drive a reliability culture.
• Sampling, resolution, Fmax, averaging, windowing, dynamic range, signal-to-noise ratio
• A/D conversion: constant and variable sampling rate
Vibration Analysis
• Spectral, time waveform and envelope analysis
Equipment Testing and Diagnostics
• Impact testing (bump tests)
• Phase analysis
• Transient analysis
• Operating deflection shape analysis
• Introduction to modal analysis
• Cross channel measurements
Fault Analysis in Detail
• Natural frequencies and resonances
• Imbalance, eccentricity and bent shaft
• Misalignment, cocked bearing and soft foot
• Mechanical looseness
• Rolling element bearing analysis
• Analysis of turbo-machinery and sleeve bearings
• Analysis of AC, DC and variable frequency drives
• Analysis of gears and belt driven machines
• Analysis of pumps, compressors and fans
• Lots of case studies and exercises for participants
Corrective Action
• Balancing and shaft alignment
• Resonance control, isolation and damping
Successful Condition Monitoring Program
• Alarms, reports, management, finances
Acceptance testing and ISO standard
What you can expect to take away
You will come away from this course with a complete understanding of vibration and phase analysis, dynamic balancing and shaft alignment, and a developing knowledge of machine dynamics and all condition monitoring technologies.
Certification (optional)
At 9.00am on Day 6, there is an optional 4-hour exam with a 70% passing grade.
The exam follows ISO 18436-2 and 18436-3 and provides 3.5 Continuing Education Unit (CEU) credits.
Registered students are given access to the online version of the course via the Mobius Institute Learning Zone™ before the class and for four months after course completion to assist them with converting the course information into practice.
No prior experience is required for attending the training course, but certification required 36 months of experience AND ISO Category 2 certification – or a minimum of 60 months experience in lieu of Category 2 certification.
Switch On: Safety Leadership
The safest workplaces are built on a culture of commitment rather than blind compliance. Switch On helps leaders and teams develop their commitment to safety so they can then create a stronger safety culture. This award-winning program has been a catalyst for safety culture transformation in businesses across Australia and around the world.
8 Core Modules
• Introduction
• Switch On Part 1
• Switch On Part 2
• Switch On Part 3
• Safe To Start Part 1
• Safe To Start Part 2
• Courageous Conversations
• Act On It
15 hrs over 2 days 15 hrs over 2 days
Course outline
Introduction
• Welcome & Introduction – set context and purpose
• Learning outcomes
• Overview of the CORE 4
• Introduction Activity – changes in safety comparison past to present – links to culture of safety performance
Switch On Part 1
• Gallery Activity – participants expectations, benefits and why we miss hazards
• TOP 4 – What is important to you?
• The three levels of Accountability
• Who is responsible for Safety? Workbook activity
• Video – impact of fatalities
Switch On Part 2
• Belief model – beliefs drive our thinking, behaviour and results
• Culture of Safety – What is it and how can we create and influence it?
• Cultural Case Study – Bud Holland
• Influencing Culture – Effective Switch On Shares
Switch On Part 3
• Above & below the line behaviour
• Group break out – Identifying current behaviours – those driving us forward and those holding us back
• Circle of control – recognising what is in our control
• Issue Safety at Home booklets – Take home tasks explained (Switch On Share preparation, home audit & share your TOP 4)
Safe to Start Part 1
• Share and practice personal switch on shares – high impact experience
• Review of key frameworks from day 1 – how to apply them at work
• Group discussion on Home safety review
• Build home safety action plan with commitments/dates/deliverables
Safe to Start Part 2
• Team activity to understand safe to start – outdoor and high impact
• Identify factors that can lead us to think we and our teams are right to start when it may not be the case
• Safe to Start – review of pre-start frameworks
Courageous Conversations
• Video – high impact on choices and their impact
• Circle of Choice – Different risk-taking behaviours individuals choose and how to influence these at home and work
• The importance of not looking the other way
• Giving and receiving Courageous Conversations
• Courageous Conversations framework
• Courageous Conversations – skills practice
Act On It
• Self-Audit – What choice will I make going forward?
• Using ideas page to summarise and identify personal actions and commitments
• Peer coaching to improve plan
• Each person publicly declares their commitments
• Personal leadership action plan at work
• Personal action plan for home
• Summary & close
What you can expect to take away
1. Create a shared belief that what we do matters in safety.
2. Increase awareness of hazard and near-miss situations and extend this awareness to home.
3. Equip participants with the skills and expertise to positively influence others.
4. Provide participants with the confidence and techniques to intervene if they see an unsafe act or condition.
5. Encourage participants to recognise and acknowledge others when they see safe acts and conditions.
6. Create individual safety action plans for your workplace.
Private Training
Whether you have 15 or 1500 people to train, we can tailor onsite training that works for you. Benefits include:
Customisation
Training can be tailored to meet the specific needs of your organisation. Content, examples, and case studies can be customised to align with your industry, culture, and strategic objectives.
Cost & convenience
Onsite training is always more cost-effective compared to public training, especially when a large number of employees requires training. Your company can save costs associated with travel, accommodation, and registration fees.
Productivity & engagement
Onsite training provides an opportunity for employees to participate in training sessions together, fostering teambuilding and collaboration. By sharing a learning experience, employees can strengthen relationships.
Relevance
Onsite training can focus on topics that are directly applicable to your organisation’s operations and industry. This ensures that the training content is highly relevant to the employees’ day-to-day work.
Confidentiality
Onsite training allows for open discussions and sharing of sensitive or confidential information. Employees can freely discuss their challenges, experiences, and specific issues related to their work.
Long-term impact
Onsite training has a lasting impact on culture and performance. Since the training is specifically designed to address the organisation’s needs, it can contribute to long-term changes in behaviour, processes, and practices.
These Leading Companies Trust Asset Schools for Private Training:
Learning Pathways
Many companies use Asset Schools as part of a Learning Pathway. Each course builds on the previous one, promoting a deeper understanding and mastery of the subject matter. The step-by-step progression helps in the development of critical thinking, problemsolving skills, and the ability to apply knowledge in practical scenarios.
This progressive approach also enables students to identify their strengths and areas for improvement, which results in a more personalized and effective learning experience. Overall, this structured pathway is integral to cultivating well-rounded, competent maintenance and reliability professionals, equipped to meet the demands of their future careers.
01. Maintenance Practitioner Pathway
Planners’ School Level 1
02. Supervisor Pathway
Planners’ School Level 1
03.
Reliability Practitioner Pathway
Planners’ School Level 2
Vibration Analysis Level 3
Planners’ School Level 1
Planners’ School Level 2
Meet Our Instructors
Drew Troyer
Principal Director, Bootleg Advisors
30+ years of expertise in sustainable manufacturing, asset management, energy & reliability engineering. Renowned author & keynote speaker. Certified Reliability Engineer & Energy Manager.
Greg Romer
Lubrication Technical Specialist, Hydrocarbon Program Consultancy
20+ years Specialised Maintenance Technician in Lubrication. Expert in strategies, risk mitigation, 5S, & training courses for tangible results. Qualifications: ICML-LLA1, MLT1, MLA3, MLE, and more.
Tim McLain
PCOO & Global Director, MRO Missing Link Supply Solutions
30+ years MRO/Materials specialist. National & Global roles for top companies. Cross-border project manager & team trainer. US-born, NZ & Aus experienced. Proud All Blacks supporter!
Michael Hooper
Tutor, Analyst and Technical Author, Noria Corporation
40 years lubrication & oil analysis expert across multiple continents. Noria Services Training Consultant. Managed labs & LIMS development. Author & presenter on lubrication & analysis.
Scott Henderson
Founder / Director / Trainer, Thermalign
Scott’s reliability journey began with 14 years in the British Army as a senior maintainer of rotary aviation assets. After relocating to Australia and gaining six years of industry experience, he founded Thermalign.
Peter Durrant
Adjunct Principal, Covaris
Navy veteran, diverse maintenance career. Senior roles in Navy, mining, and resources. Maintenance consultant. Expert in work management, sustainable change. Dip Eng & MBA Tech Mgmt.
Mike Greyling
Adjunct Principal, Covaris
Seasoned asset management leader with 35+ years in aviation, smelting, mining. Proven excellence in maintenance, reliability, risk management, stakeholder engagement, Six Sigma expertise, SAP leadership.
Nikki McMurray
Senior Consultant, Actrua
30+ years in adult education & hazardous industries consulting. Hands-on facilitator & trainer in mining, rail, construction, and more. Host of ‘Leadership in Hazardous Industries’ Podcast.
Kylie Nash
Principal Engineer, Provecta Process Automation
30+ years engineer in electricity generation. AGL Macquarie veteran – asset management, reliability, team leadership. Skilled in problem-solving, change projects. BEng & MBA Tech Mgmt.
Brian Ropitini
Director, Ara Ake, New Zealand
Accomplished facilitator, coach & mentor. Fitter & turner turned senior leader. Led multi-million-ton methanol plants & global teams at Methanex. Exceptional communicator & visionary.
Chris Cunningham
Principal, Covaris
Leading asset management specialist with 20+ years experience. Diverse industries: power, nuclear, mining, defense & more. Globally renowned in change & risk management, optimized asset performance.
Dr Bob Platfoot
Principal and Managing Director, Covaris
30+ years in maintenance & asset management across diverse sectors. PhD in fluid dynamics & life assessment. Founder of Covaris, driving asset management transformation & ISO 55001 implementation.
Meet Our Team
61 403 809 312
61 2 9955 7400
61 2 9955 7400
Asset Schools is part of the MAINSTREAM group.
Founded in 1996, MAINSTREAM serves asset-intensive industries with research, information, events, and training courses that celebrate the successes, accelerate the careers, and optimise the performance of Asset, Reliability and Maintenance professionals.
CONFERENCE & SUMMIT
ANZ’s largest, most progressive Asset Management Conference in Melbourne and Summit in Perth.
ASSET SCHOOLS
Training courses and capability development for maintenance, reliability, trades, operators, and teams
NETWORK
Online platform offering case studies, content, discussion forums, workshops, and networking round tables.
MASTERCLASSES
Monthly expert-led online masterclasses, including interactive Q&A.
UPSTREAM
Fortnightly community newsletter featuring maintenance and reliability tips, tricks, and case studies.
INFORMATION
Research, polls, surveys, and sentiment reports.
RELIABILITY HERO
Podcast series hosted by Andrew Daddo, featuring interviews with Australian and international maintenance and reliability leaders and special guests.
MAINCOMZ
Visual and digital solutions to simplify complex and critical maintenance and safety processes.
