About This Course
5-day course outline titled “Adding Value to Maintenance through Reliability”. This
course is ideal for maintenance managers, reliability engineers, planners, and plant
supervisors who want to elevate their maintenance programs through a focus on
reliability principles, tools, and practices.
5-Day Course Outline
Day 01 (FOUNDATIONS OF MAINTENANCE AND RELIABILITY)
Objective: Establish a strong base of maintenance principles
and how reliability drives business value.
Sessions:
1. Introduction to Modern Maintenance
- Maintenance evolution: Reactive – Preventive – Predictive -Proactive
- Maintenance strategies overview
- The true cost of equipment failure
2. Reliability as a Business Value
- Dening reliability in the maintenance context
- Asset performance vs. business performance
- Maintenance maturity model
3. Key Reliability Concepts
- MTTR, MTBF, OEE, RCM, TPM
- Cost of poor reliability vs. value of uptime
4. Maintenance & Reliability Best Practices
- World-class benchmarks
- Culture of reliability and ownership
DAY 02 (ASSET MANAGEMENT AND CRITICALITY ANALYSIS)
Objective: Learn how to prioritize and manage assets for
maximum reliability and impact.
Sessions:
1. Asset Lifecycle and Reliability
- Lifecycle cost analysis
- Role of maintenance throughout asset life
2. Asset Hierarchy and Data Integrity
- Asset structure and labeling
- CMMS data accuracy and standardization
3. Criticality Analysis
- Asset classication: Critical, semi-critical, non-critical
- Risk-based prioritization methods
4. Failure Modes, Eects & Criticality Analysis (FMECA)
- Identifying failure modes
- Assessing impact and likelihood
- Decision matrix for selecting strategies
DAY 03 (RELIABILITY-CENTERED MAINTENANCE (RCM) AND PREDICTIVE TECHNIQUES)
Objective: Dive into tools and strategies that anticipate and
prevent failures.
Sessions:
1. Introduction to RCM
- Principles and process steps
- RCM vs. traditional PM
2. Developing a RCM Program
- Asset data requirements
- Task selection logic (proactive, default, redesign)
3. Condition-Based & Predictive Maintenance
- Vibration, thermography, ultrasound, oil analysis
- Integrating PdM data into CMMS
4. Using CMMS for Reliability Strategy Execution
- Setting up RCM workows
- Failure codes, history, trends
- Data-driven decision making
Day 04 (PERFORMANCE MEASUREMENT, ROOT CAUSE ANALYSIS, AND CONTINUOUS IMPROVEMENT)
Objective: Use data and analytical tools to reduce failures
and improve reliability.
Sessions:
1. Maintenance & Reliability KPIs
- MTBF, MTTR, PM compliance, Backlog analysis
- KPIs for cost, quality, and uptime
2. Root Cause Analysis (RCA)
- 5 Whys, Fishbone (Ishikawa), Fault Tree Analysis
- Conducting an RCA step-by-step
3. Continuous Improvement & Kaizen
- Reliability improvement plans
- Feedback loops and audits
4. Case Studies and Benchmarks
- Success stories: from reactive to reliable
- Common pitfalls and lessons learned
DAY 05 (LEADERSHIP, CULTURE, AND STRATEGY FOR RELIABILITY EXCELLENCE)
Objective: Learn to lead a reliability-focused maintenance
organization.
Sessions:
1. Building a Reliability Culture
- Cross-functional collaboration: Ops, Maintenance, Engineering
- Leadership alignment and empowerment
2. Organizational Structure & Roles
- Planners, schedulers, reliability engineers
- Job descriptions and competency frameworks
3. Training, Communication, and Change Management
- Driving engagement at all levels
- Sustaining momentum with reliability champions
4. Strategic Planning and Roadmapping
- Creating a 1–3 year reliability improvement roadmap
- Linking to corporate KPIs and nancial performance