🎯 Course Description:
This intensive 5-day course equips participants with the strategic tools, methodologies, and best practices needed for effective and modern maintenance management in industrial and infrastructure settings. Emphasizing asset performance, risk-based decision-making, predictive maintenance, and digital integration, the course moves beyond basic maintenance to focus on achieving world-class reliability, efficiency, and cost control.
Participants will explore maintenance strategies, KPIs, failure analysis, CMMS, and RCM through real-life examples, case studies, and interactive group exercises.
👥 Who Should Attend:
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Maintenance and reliability managers
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Plant and operations engineers
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Asset integrity and facilities engineers
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CMMS administrators and planners
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Industrial maintenance supervisors
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Professionals involved in asset lifecycle management
🗓️ Day 1: Evolution and Strategy of Maintenance Management
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Maintenance Evolution – Reactive to Predictive to Proactive |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Types of Maintenance – Preventive, Predictive, RCM, TPM |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Strategic Maintenance Planning – Aligning with business goals |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Maintenance maturity assessment of participant’s site |
🗓️ Day 2: Reliability, KPIs, and Performance Measurement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Reliability Engineering Principles – MTBF, MTTR, availability |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Key Maintenance KPIs – Backlog, compliance, wrench time, OEE |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Maintenance Dashboards & Reporting – Visualization best practices |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: KPI design and analysis using sample plant data |
🗓️ Day 3: Failure Analysis and Risk-Based Maintenance
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Failure Modes & Effects Analysis (FMEA) |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Root Cause Analysis (RCA) – 5 Whys, Fishbone, fault trees |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Risk-Based Maintenance (RBM) – Asset criticality, prioritization |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: RCA and FMEA exercise for a failed plant asset |
🗓️ Day 4: CMMS, Planning & Scheduling, and Digital Tools
| Time | Topic |
|---|---|
| 08:30 – 10:00 | CMMS Best Practices – Configuration, workflows, data quality |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Maintenance Planning and Scheduling – Backlog management, job kitting |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Digital Maintenance Tools – IoT, mobile inspections, AI integration |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Maintenance schedule and job plan using CMMS templates |
🗓️ Day 5: World-Class Maintenance & Continuous Improvement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | World-Class Maintenance Models – Lean, TPM, Six Sigma |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Cost-Benefit of Advanced Maintenance – ROI of predictive and condition-based |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Build a roadmap to improve a maintenance program |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Course Materials Provided:
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Maintenance management strategy workbook
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FMEA and RCA templates (editable)
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CMMS configuration and workflow checklist
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KPI dashboard samples (Excel and Power BI)
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Maintenance planning toolkit (job plan, backlog template)
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Case studies on TPM, predictive maintenance, and lean maintenance
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Reference guide: ISO 55000 and asset management integration
