Course Details

Objective

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

• Understand the different types of maintenance processes and their applications.
• Learn how to develop and implement a maintenance strategy that suits their organization’s needs.
• Gain insight into the importance of maintenance planning, scheduling, and resource management.
• Understand the role of predictive and condition-based monitoring in enhancing maintenance efficiency.
• Learn how to evaluate and improve the effectiveness of maintenance processes in reducing downtime and operational costs.

Content

Day 1: Introduction to Maintenance Processes

• Overview of industrial maintenance and its importance
• Types of maintenance: Corrective, Preventive, Predictive, and Condition-Based Maintenance
• Key maintenance objectives: maximizing uptime, improving reliability, and reducing costs
• Maintenance lifecycle: from design and installation to operation and decommissioning
• The role of maintenance in overall plant performance and productivity

Day 2: Preventive and Corrective Maintenance

• Overview of preventive maintenance: scheduling, tasks, and benefits
• Corrective maintenance: troubleshooting, repair, and handling unplanned downtime
• Planning and prioritizing maintenance activities
• Key performance indicators (KPIs) for preventive and corrective maintenance
• Maintenance work orders, checklists, and documentation

Day 3: Predictive and Condition-Based Maintenance

• Understanding predictive maintenance: principles and technologies
• Condition monitoring techniques (e.g., vibration analysis, thermography, oil analysis)
• Using data for predictive analysis and early fault detection
• Benefits of predictive maintenance over traditional methods
• Integrating predictive maintenance into overall maintenance strategies

Day 4: Maintenance Planning and Scheduling

• The importance of effective planning and scheduling in maintenance
• Developing a maintenance plan: goals, resources, and timelines
• Best practices for scheduling maintenance activities
• Resource management: staffing, equipment, and materials
• Managing maintenance backlogs and prioritizing work

Day 5: Performance Evaluation and Continuous Improvement

• Evaluating maintenance effectiveness and measuring performance
• Tools and techniques for tracking maintenance performance (e.g., downtime analysis, MTTR, MTBF)
• Root cause analysis and failure analysis techniques
• Strategies for continuous improvement in maintenance processes
• Leveraging technology (e.g., CMMS) to optimize maintenance operations

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions