Course Details

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

• Maintenance and Reliability Engineers
• Maintenance Planners and Supervisors
• Operations and Production Engineers
• Asset Integrity, Mechanical, and Plant Engineers
• Engineering Managers and Technical Support Personnel
• Anyone involved in maintenance strategy development or reliability 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 the principles and purpose of Reliability-Centered Maintenance
• Select systems and equipment for RCM analysis
• Identify equipment functions, functional failures, and failure modes
• Apply FMEA and RCM decision logic to determine optimal maintenance tasks
• Develop and implement effective RCM-based maintenance programs
• Evaluate RCM effectiveness and integrate it with asset management practices

DAY 1

Introduction to RCM and Reliability Concepts

• Welcome and Introduction
• Pre-Test
• Role of RCM in Modern Maintenance Management
• Reliability, Availability, and Maintainability Principles
• Failure Behavior, Failure Patterns, and PF Curve
• RCM Standards and Industry Applications
• Seven Questions of RCM
• Exercise

DAY 2

System Selection and Functional Analysis

• Criteria for Selecting Systems for RCM Study
• Defining System Boundaries and Operational Context
• Equipment Functions and Performance Standards
• Identifying Functional Failures
• Introduction to System Block Diagrams
• Exercise

DAY 3

Failure Modes and Effects Analysis (FMEA)

• Identifying Failure Modes and Their Causes
• Understanding Failure Effects and Consequences
• Categorizing Failure Consequences: Safety, Environmental, Operational, Economic
• Building the FMEA Worksheet
• Gathering and Interpreting Failure Data
• Exercise

DAY 4

RCM Decision Logic and Task Selection

• RCM Decision Logic Flow and Its Application
• Preventive, Predictive, and Condition-Based Tasks
• Failure-Finding, Redesign, and Run-to-Failure Decisions
• Selecting Cost-Effective and Feasible Maintenance Strategies
• Developing Maintenance Plans from RCM Analysis
• Exercise

DAY 5

RCM Implementation, Review, and Course Wrap-up

• Integrating RCM with CMMS and Asset Management Systems
• Managing Change and Ensuring Cross-Functional Involvement
• Reviewing and Updating RCM Programs
• Measuring Performance and Continuous Improvement
• Post-Test
• Certificate Ceremony