Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Maintenance and Reliability Engineers
• Maintenance Supervisors and Planners
• Operations and Production Engineers
• Plant Managers and Asset Management Personnel
• Engineering Technicians and Maintenance Teams
• Anyone involved in maintenance optimization or equipment performance improvement

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand preventive, predictive, and cost-effective maintenance concepts
• Develop and improve preventive maintenance (PM) programs
• Apply condition-based monitoring techniques for predictive maintenance
• Identify equipment failure modes and select appropriate maintenance strategies
• Measure maintenance performance using KPIs and cost analyses
• Implement effective maintenance plans that reduce downtime and improve reliability

DAY 1

Introduction to Maintenance Techniques and Reliability Concepts

• Welcome and Introduction
• Pre-Test
• Overview of Modern Maintenance Approaches
• Role of Maintenance in Asset Performance and Reliability
• Failure Modes, Failure Patterns, and the PF Curve
• Comparison of Run-to-Failure, Preventive, and Predictive Maintenance
• Exercise

DAY 2

Preventive Maintenance (PM) Strategy and Implementation

• Principles of Preventive Maintenance
• PM Task Selection and Optimization
• Developing PM Procedures and Checklists
• Planning PM Intervals and Resource Requirements
• Balancing PM Workload and Minimizing Over-Maintenance
• Documentation and PM Standardization
• Exercise

DAY 3

Predictive and Condition-Based Maintenance (CBM)

• Fundamentals of Predictive Maintenance
• Vibration Analysis, Thermography, and Oil Analysis
• Ultrasound Testing and Motor Current Signature Analysis
• Condition Monitoring Data Interpretation
• Integrating CBM with PM Programs
• Digital Tools for Predictive Maintenance
• Exercise
   

DAY 4

Cost-Effective Maintenance and Optimization Tools

• Cost of Maintenance vs. Cost of Failure
• Maintenance Cost Analysis Techniques
• Reliability-Centered Maintenance (RCM) Overview
• Criticality Analysis and Prioritization
• Performance Indicators: MTBF, MTTR, Availability
• Strategies for Reducing Maintenance Costs
• Exercise

DAY 5

Maintenance Improvement, Performance Tracking, and Course Wrap-up

• Building a Continuous Maintenance Improvement Program
• Maintenance Audits and Review Processes
• Measuring PM and CBM Effectiveness
• Linking Maintenance Activities to Operational and Business Goals
• Post-Test
• Certificate Ceremony