🎯 Course Description:
This in-depth 5-day training program provides professionals with the knowledge and skills to develop, implement, and optimize Preventive Maintenance (PM) and Predictive Maintenance (PdM) strategies. The course emphasizes minimizing unplanned failures, optimizing asset life cycles, and enhancing plant availability and reliability.
Participants will learn how to design PM programs, select the right PdM technologies (vibration analysis, thermography, oil analysis, etc.), interpret condition monitoring data, and transition from time-based to condition-based maintenance.
👥 Who Should Attend:
-
Maintenance engineers and supervisors
-
Reliability and asset management professionals
-
Mechanical and electrical technicians
-
Condition monitoring specialists
-
Operations and plant engineers
-
CMMS and data analysts
🗓️ Day 1: Fundamentals of Maintenance and Reliability
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Maintenance Strategy Overview – Reactive, preventive, predictive, RCM |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Understanding Equipment Failure – Types, causes, and failure curves |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Principles of Preventive Maintenance (PM) – Time-based & usage-based |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Assessing current maintenance strategy in participants’ plants |
🗓️ Day 2: Designing and Implementing a Preventive Maintenance Program
| Time | Topic |
|---|---|
| 08:30 – 10:00 | PM Task Identification and Development – OEM vs experience-based tasks |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | PM Scheduling and Frequency Optimization – Avoiding over/under maintenance |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | PM Documentation and Work Order Processes |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Create a PM plan for a selected asset or equipment class |
🗓️ Day 3: Predictive Maintenance (PdM) Techniques and Tools
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Introduction to Predictive Maintenance (PdM) – Concepts & benefits |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Condition Monitoring Methods – Vibration, thermography, oil analysis |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Using Ultrasonic, Motor Current, and Acoustic Emissions Techniques |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Selecting appropriate PdM methods for different asset types |
🗓️ Day 4: Data Collection, Analysis, and CMMS Integration
| Time | Topic |
|---|---|
| 08:30 – 10:00 | PdM Data Collection & Storage – Manual vs online condition monitoring |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Interpreting PdM Data – Trends, thresholds, alarms, and decisions |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Integrating PdM and PM with CMMS Systems |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Build a dashboard of condition indicators for selected equipment |
🗓️ Day 5: Strategy Optimization and Reliability Improvement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Maintenance Optimization Techniques – FMEA, criticality ranking, maintenance tactics |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Key Performance Indicators (KPIs) – PM compliance, MTBF, MTTR, asset availability |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Develop a combined PM/PdM strategy for a critical system |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Course Materials Provided:
-
PM program templates and checklists
-
PdM technique overview sheets (vibration, oil, thermography, ultrasound)
-
Sample CMMS reports and dashboards
-
KPI tracking spreadsheet
-
Failure mode and maintenance tactic selection matrix
-
Case studies from oil & gas, power, and manufacturing industries
