Know About Your Trainer

Mr. Ahmed Kotb is a freelance expert facilitator/consultant/trainer and executive coach in delivering strategic courses and masterclasses at corporate level internationally

He is a very pragmatic trainer through his use of an integrated learning approach which is practical, actionable, life relevant, competency based and results-oriented

Mr. Ahmed Kotb is an Asset Management and Reliability Team Leader with more than 36 years of experience in Maintenance and Reliability, Maintenance Planning and Scheduling and Asset Management fields.

Course Overview

  • Reliability Centered Maintenance (RCM) is not another Maintenance Strategy or Maintenance Program, RCM is a systematic approach to maintenance planning and decision-making that aims to ensure the reliability and performance of assets while minimizing costs.
  • Preventive maintenance is so institutionalized in many facilities today that facilities engineers don’t even stop to question whether their maintenance practices affect system reliability. Up to 50 percent of unplanned downtime occurs in “ serviced “ systems within the previous 7 days, according to research from the Palo Alto, CA-based Electric Power Research Institute and the U.S. Navy. So, if the goal of the preventive maintenance program is truly to prevent production interruptions, it’s time for maintenance engineers to reconsider their approach to maintenance.
  • Reliability-cantered maintenance is much more than just another way to do maintenance. It’s a way of looking at system performance in terms of the impact of a failure and then mitigating those results by design, detection, or effective maintenance.
  • “RCM is one of the most powerful asset management processes that can be employed. RCM’s principles are so diverse that they can be applied to any asset—an airplane, nuclear power plant, truck, tank, ship, manufacturing plant, offshore oil platform, mobile air conditioning unit, tow tractor, jet engine, a single pump, or an engine control unit. RCM principles can be widely applied to an entire asset or more narrowly applied to select pieces of equipment”. The RCM Solution by Nancy Regan.
  • This comprehensive 5-day course is designed to provide participants with a thorough understanding of RCM principles, methodologies, and practical applications. Through a combination of theoretical lectures and case studies, participants will learn how to implement RCM effectively in their organizations.

What You Will Learn


Day 1 – Understanding How RCM Evolved from the Main Maintenance Strategies
  • Where is Maintenance in the Big Picture?
  • Why do we need to understand Maintenance First?
  • RCM Evolution
  • Reactive Maintenance
  • Run to Failure Maintenance
  • Corrective Maintenance
  • Preventive Maintenance (PM)
  • Condition Based Maintenance (CBM)
  • Predictive Maintenance (PdM)


Day 2 – Asset Criticality Assessment as a Key Step for any Maintenance and Reliability Initiative – Understanding Reliability Centered Maintenance (RCM)
  • How to perform Asset Criticality analysis?
  • What is Reliability Centered Maintenance (RCM)?
  • RCM History
  • RCM Published Guidelines and Standards
  • RCM Objectives
  • RCM Principles
  • RCM Integrates Maintenance Strategies
  • RCM Benefits
  • Operating Context
  • RCM Process Overview
  • Types of RCM
  • RCM Analysis
  • Building the Strategy Team
  • Assess Current Maintenance Processes
  • RCM Analysis sequence
  • RCM Procedure


Day-3 Reliability Centered Maintenance (RCM) Implementation Steps
  • Step 1: System Selection and Information Collection
  • Step 2: System Boundary Definition
  • Step 3: System Description and Functional Block Diagram
  • Step 4: System Functions and Functional Failures
  • Step 5: Failure Mode and Effects Analysis
  • What is Failure Mode and Effects Analysis (FMEA)?
  • What is Failure Mode?
  • Example of Failure Mode Identification
  • Hidden and Evident Failures
  • What is Failure Cause?
  • Failure Effects
  • Failure Consequences
  • Example of Step 5: FMEA
  • The RCM Decision Process
  • Step 6: Logic Tree Analysis (LTA)
  • Step 7: Selection of Maintenance Tasks
  • Step 8: Task Packaging and Implementation
  • Step 9: Making the Program a Living One — Continuous Improvements
  • Summary of RCM
  • RCM Examples


Day-4 Managing RCM program through the CMMS – KPIs & RCM Metrics – RCM Project Guide
  • What’s the difference between FMEA and RCM?
  • FMEA as a Standing Alone Analysis (not part of RCM)
  • FMEA Process
  • Example of FMEA Worksheet
  • FMEA Worksheet details
  • Calculating the RPN
  • Examples of FMEA
  • Example of FMEA from NASA reference
  • Is your CMMS/EAM capable to capture the RCM analysis requirements?
  • Current failure code hierarchy in most CMMS/EAM systems
  • How to configure your system to capture the RCM analysis requirements on the go?
  • Manage used Key Performance Indicators (KPIs)
  • What is KPIs?
  • Leading & Lagging KPIs, what is the Difference?
  • Examples of Key Performance Indicators (KPIs)
  • Relevant RCM Key Performance Indicators (KPIs)

DAY FIVE (Half Day)

Day-5 RCM implementation best practices and lessons learned – Project Guide
  • RCM implementation best practices and lessons learned
  • Project Guide for RCM Implementation
  • Section-1: Introduction
  • Section-2: An RCM Primer
  • Section-3: Deciding to Conduct an RCM Project
  • Section-4: Valuable Lessons Learned by Other Organizations
  • Section-5: Completing an RCM Study
  • Section-6: Implementing the RCM Study
  • Section-7: Measuring the Benefits
  • Section-8: Sustaining an RCM Program