🎯 Course Description:
This comprehensive 5-day training course provides participants with a deep understanding of Reliability Centered Maintenance (RCM) — a structured, risk-based methodology for developing cost-effective, efficient, and reliability-focused maintenance strategies.
Participants will explore the RCM process, failure modes analysis, criticality assessment, functional failure effects, and task selection logic, with a focus on real-world application. The course integrates theory with hands-on workshops to ensure participants can identify critical assets, analyze failure consequences, and implement RCM within their organizations.
👥 Who Should Attend:
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Maintenance and reliability engineers
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Maintenance planners and supervisors
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Plant and operations engineers
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Asset integrity and CMMS professionals
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Engineering consultants and maintenance contractors
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Project engineers and asset managers
🗓️ Day 1: Introduction to RCM and Asset Reliability
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | What is RCM? – History, objectives, and industry relevance |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Asset Reliability Principles – MTBF, availability, lifecycle cost |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | The Seven Questions of RCM – Intro to the RCM logic tree |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Case Study Introduction – System selection for RCM analysis |
🗓️ Day 2: Functional Failure Analysis and Failure Modes
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Identifying Functions and Functional Failures – System performance expectations |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Failure Modes and Effects Analysis (FMEA) – Failure modes, causes, consequences |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Failure Consequences Categories – Safety, operational, non-operational, hidden |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Perform FMEA for selected components |
🗓️ Day 3: Task Selection and Maintenance Strategy Development
| Time | Topic |
|---|---|
| 08:30 – 10:00 | RCM Decision Logic – How to choose the right maintenance task |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Preventive, Predictive, and Failure-Finding Tasks – Selection criteria |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | When No Task is Applicable – Default actions and redesign recommendations |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Develop an RCM decision logic tree for a case system |
🗓️ Day 4: Implementation, CMMS Integration, and Performance Monitoring
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Implementing RCM in the Real World – Pilot selection, resource planning |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Integrating RCM into CMMS and Maintenance Planning – Task loading, hierarchy setup |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Measuring RCM Performance – KPIs, PM effectiveness, feedback loops |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Develop implementation roadmap for an RCM program |
🗓️ Day 5: RCM Facilitation and Group Exercise
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Facilitating an RCM Analysis Session – Team roles, data gathering, conflict resolution |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Common Pitfalls and Success Factors in RCM Implementation |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Complete an RCM analysis from function to maintenance task recommendations |
| 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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RCM process flowcharts and logic tree templates
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FMEA and criticality assessment worksheets
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Maintenance task selection guide
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CMMS data mapping for RCM integration
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KPI dashboard samples for RCM implementation
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Case studies (power generation, oil & gas, manufacturing)
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Facilitator’s checklist and RCM team charter template
