Applied Engineering & Consulting

NFPA 70E Training

Conducted by NFPA (trainer from USA)
Course language: English
Passed exam: a certificate of NFPA Educational Achievement will be provided.

Limited spaces are available. First come first serve.
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15 Rules every maintenance managers should know:

📌 (Save this and stick it in your planning office)

✅ 01. Know Your Equipment Before You Touch It
Walk the floor. Learn the sounds, the smells, the vibrations.
No tool replaces a tech who can hear a bearing going bad from across the shop.

✅ 02. The Work Order Is Sacred
If it's not in a work order, it didn't happen.
No documentation, no history. No history, no improvement.

✅ 03. Root Cause Over Quick Fix
Anyone can replace the part. The job is figuring out why it failed.
Stop treating symptoms. Treat the system.

✅ 04. Planned vs. Reactive Ratio
80% planned, 20% reactive is the target.
If you're running 50/50, you're not maintaining. You're firefighting.

✅ 05. Criticality Rankings
Not all equipment matters equally.
A conveyor belt and a boiler feed pump do not deserve the same PM frequency.

✅ 06. Failure Modes
Every piece of equipment has a preferred way to die.
Learn it before it teaches you the hard way.

✅ 07. Spare Parts Strategy
Too much inventory is waste. Too little is a $200K production loss at 2am.
The sweet spot requires knowing your equipment, not guessing.

✅ 08. Operator Care
The best reliability program starts with the operator.
Clean, inspect, lubricate. Simple. Almost nobody does it consistently.

✅ 09. PM Optimization
Not every PM adds value. Some are calendar rituals nobody questions.
If you can't explain what a PM prevents, cut it.

✅ 10. Backlog Management
A healthy backlog is 2-4 weeks of work.
Zero backlog means you're not finding enough. Ten weeks means you're drowning.

✅ 11. Wrench Time
How much of a technician's shift is actual hands-on-tools work?
Industry average is 35%. World class is 55-65%. Measure before you staff up.

✅ 12. Shutdown Planning
The outage window is not the time to figure out what needs doing.
Plan it 90 days out. Scope it, stage it, execute it.

✅ 13. Reliability vs. Maintenance
Maintenance fixes things. Reliability prevents the fix from being needed.
If your team only does the first, you're running in circles.

✅ 14. Condition Monitoring
Vibration, oil analysis, thermography. The data tells you what's coming.
Not because it's fancy technology. Because it beats waiting for the catastrophic failure.

✅ 15. Continuous Improvement
Every breakdown is a lesson. Every PM review is an opportunity.
The plants that win aren't the ones with the best equipment. They're the ones that never stop adjusting.

The managers who get these right sleep better at night.
And their teams actually want to show up in the morning.

Credit: LinkedIn post Ivan Getov

Completion of Power Transformer Site Acceptance Test (SAT).

For transformer testing or HV testing, contact APENC.

🔧 Maintenance KPIs That Actually Drive Performance

Most organizations track maintenance KPIs…
but not all KPIs create value.

The difference?
👉 Tracking metrics with clear purpose, formulas, and action.

Here are the Maintenance KPIs that truly matter—with how to measure them:

🔹 Reliability

• Breakdown Frequency = Number of Breakdowns / Total Operating Time
• MTBF = Total Operating Time / Number of Failures
• Reliability (R) = e^(-t / MTBF)
• Abnormalities Closed on Time (%) = (Closed on Time / Total Abnormalities) × 100

🔹 Maintainability

• MTTR = Total Downtime / Number of Failures
• MTTF = Total Time in Service / Number of Failures
• Failure Rate (λ) = Number of Failures / Total Time in Service
• Emergency Work (%) = (Emergency Work Hours / Total Maintenance Hours) × 100

🔹 Planning & Strategy

• PM Compliance (%) = (PMs Completed on Time / Total PMs Due) × 100
• Schedule Compliance (%) = (Work Completed as Scheduled / Total Work Scheduled) × 100
• CBM Coverage (%) = (Assets with CBM / Total Critical Assets) × 100
• Spare Availability (%) = (Critical Spares Available / Total Critical Spares) × 100

🔹 Cost & Continuous Improvement

• Maintenance Cost (%) = (Total Maintenance Cost / Replacement Asset Value) × 100
• Energy Performance (%) = (Actual Energy Use / Baseline Energy Use) × 100
• Kaizen Completion (%) = (Kaizen Completed / Kaizen Planned) × 100
• Knowledge Standardization (%) = (Documents Completed / Documents Planned) × 100

📊 Key Insight:
You don’t improve maintenance by tracking more KPIs…
You improve it by tracking the right KPIs consistently and acting on them.

💡 Which KPI has made the biggest impact in your plant?

Credit to: LinkedIn post Wael Rahma

Understanding failure before it happens is the real game-changer in maintenance.

This visual highlights the P–F Curve (Potential Failure to Functional Failure) — a powerful concept that shows how asset condition degrades over time and where we have opportunities to act.

🔹 Precision Maintenance (I–P stage) ensures we start right — proper installation, alignment, and setup prevent early defects.
🔹 Predictive Maintenance (P–F stage) allows us to detect issues early using tools like vibration analysis, oil analysis, and thermography.
🔹 Preventive Maintenance helps manage visible deterioration before it escalates.
🔹 Run-to-Failure? That’s where costs, downtime, and safety risks peak.

What stands out most is the safety perspective:
👉 Failures don’t just impact equipment — they progress from unsafe conditions to near misses, injuries, and even fatalities.

The earlier we act, the safer, cheaper, and more reliable our operations become.

Are you leveraging the full potential of your P–F interval, or reacting too late?

Credit to LinkedIn post Anil Kumar