About This Course

5-day course outline for “Continuous Maintenance Improvement”, designed to equip maintenance professionals with the mindset, tools, and systems necessary to drive ongoing performance improvement.
This course is aimed at maintenance managers, supervisors, planners, reliability engineers, and continuous improvement (CI) teams.

5-Day Course Outline

Day 01 (INTRODUCTION TO MAINTENANCE AND CONTINUOUS IMPROVEMENT)

Objective: Understand the principles of continuous
improvement (CI) in a maintenance context and how to
evaluate current practices.

Sessions:

1. Modern Maintenance Overview

  • Evolution: Reactive – Preventive – Predictive – Proactive
  • World-class maintenance characteristics

2. What is Continuous Improvement (CI)?

  • CI principles (Kaizen, PDCA, Lean)
  • Why CI is essential in maintenance
  • Benets of CI in uptime, safety, and cost

3. Assessing Current Maintenance Performance

  • Maintenance maturity models
  • Maintenance audits and gap analysis
  • Identifying improvement opportunities

4. Maintenance Strategy Alignment

  • Aligning with business goals
  • Stakeholder involvement and expectations

DAY 02 (MAINTENANCE PLANNING, SCHEDULING, AND EXECUTION EXCELLENCE)

Objective: Improve the core functions of maintenance execution
through structured planning and scheduling.

Sessions:

1. Planning and Scheduling Fundamentals

  • Roles of planner, scheduler, and supervisor
  • Job plans, work packages, and backlog management

2. Eective Work Management

  • Work order lifecycle (request to close)
  • Preventive vs. corrective work ratio

3. Maintenance Workow Optimization

  • Standard work
  • Eliminating waste in maintenance processes (Lean thinking)

4. Measuring and Improving Execution

  • Wrench time analysis
  • Planning KPIs (schedule compliance, planning eciency)

DAY 03 (DATA-DRIVEN MAINTENANCE AND ROOT CAUSE ANALYSIS)

Objective: Leverage data and analysis to drive improvement
and eliminate recurring problems.

Sessions:

1.Using Data for Decision-Making

  • Data sources: CMMS, sensors, inspections
  • Quality of maintenance data (failure codes, closeout notes)

2. Maintenance Metrics and KPIs

  • MTBF, MTTR, OEE, Backlog, PM compliance
  • Using dashboards and reports to drive behavior

3. Root Cause Analysis (RCA)

  • RCA tools: 5 Whys, Fishbone Diagram, Pareto Analysis
  • How to structure and lead an RCA

4. Failure Elimination and Defect Elimination

  • Chronic vs. sporadic failures
  • Defect tagging and elimination workow

Day 04 (RELIABILITY, LEAN, AND CONTINUOUS IMPROVEMENT TOOLS)

Objective: Introduce Lean and reliability tools that support
maintenance improvement efforts.

Sessions:

1. Introduction to Reliability Tools

  • RCM (Reliability-Centered Maintenance)
  • FMEA/FMECA
  • Criticality Analysis

2. Lean Maintenance Tools

  • 5S in maintenance areas
  • Standard work and visual controls
  • Value stream mapping for maintenance

3. Kaizen Events and Improvement Projects

  • Planning and executing a maintenance Kaizen
  • Team engagement and facilitation

4. Change Management

  • Overcoming resistance
  • Building a culture of continuous improvement

DAY 05 (STRATEGY DEPLOYMENT AND SUSTAINING IMPROVEMENT)

Objective: Learn how to institutionalize CI in the maintenance
organization for long-term results.

Sessions:

1. CI Roadmapping and Strategic Planning

  • Short-, mid-, and long-term CI goals
  • Linking CI projects to KPIs and ROI

2. CI Governance and Leadership

  • CI committees or champions
  • Coaching and accountability structures

3. Training and Workforce Development

  • Skill gap analysis and development plans
  • Training matrix and certication paths

4. Capstone Workshop: Maintenance CI Plan

  • Team activity: develop and present a real or hypothetical
  • maintenance improvement project plan
  • Peer review and feedback

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