🎯 Course Description:
This intensive 5-day course is designed to provide professionals with a comprehensive understanding of preventive and corrective maintenance strategies to improve equipment reliability, plant availability, and operational safety. Participants will explore maintenance planning, execution, documentation, and continuous improvement with a practical approach that includes failure analysis, scheduling, CMMS utilization, and performance tracking.
The course includes case studies, planning templates, and real-world exercises to help participants build a resilient maintenance strategy tailored to their industry.
👥 Who Should Attend:
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Maintenance planners and supervisors
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Mechanical and electrical technicians
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Reliability and asset integrity engineers
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Plant managers and operations personnel
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CMMS users and maintenance administrators
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Engineers transitioning into maintenance roles
🗓️ Day 1: Maintenance Fundamentals and Classification
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Maintenance Overview – Types: Corrective, Preventive, Predictive |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Maintenance Strategies Evolution – From reactive to proactive |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Roles and Responsibilities in Maintenance Organizations |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Maintenance strategy gap analysis for participants’ sites |
🗓️ Day 2: Preventive Maintenance (PM) Strategy and Planning
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Principles of Preventive Maintenance – Time-based vs usage-based |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Creating a Preventive Maintenance Plan – Asset hierarchy, task lists |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | PM Optimization – Avoiding over- and under-maintenance |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Develop a PM plan for a selected equipment/system |
🗓️ Day 3: Corrective Maintenance (CM) and Work Execution
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Corrective Maintenance Types – Run-to-failure, emergency, scheduled |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Failure Reporting and Documentation – Tags, notifications, records |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Work Order Management and Job Planning – Tools, spares, labor |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Building a complete CM case from failure report to repair |
🗓️ Day 4: CMMS, Scheduling, and Performance Measurement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Using CMMS Effectively – Work order flow, asset registry, reports |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Maintenance Scheduling – Weekly plans, backlog, shutdown coordination |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Maintenance KPIs and Dashboards – Backlog, compliance, response time |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: PM & CM scheduling exercise using CMMS templates |
🗓️ Day 5: Root Cause, Continuous Improvement & Best Practices
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Root Cause Analysis for Maintenance Failures – Tools: 5 Whys, Pareto, RCA |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Continuous Improvement in Maintenance – Audits, feedback, kaizen loops |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Analyze, improve and defend a combined PM/CM strategy |
| 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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Preventive maintenance schedule templates
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Corrective maintenance work order forms
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Maintenance strategy development guide
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KPI tracking spreadsheet and dashboard sample
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CMMS data entry and process checklist
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RCA toolkit (templates, diagrams, checklists)
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Case studies from various industries (oil & gas, utilities, manufacturing)
