COURSE OVERVIEW:

While proactive maintenance is the goal, the reality of industrial operations involves managing failures when they occur. This course focuses on the "Corrective Maintenance" phase, emphasizing that a repair is not successful unless it is performed with precision and the root cause is addressed to prevent recurrence. It provides a structured approach to troubleshooting, precision repair techniques, and the critical feedback loop required to turn a failure into a learning opportunity.

The scope of this training involves the technical skills of rapid diagnosis and high quality restoration. Participants will learn how to use logical troubleshooting frameworks, such as the "Half-Split" method and "Fishbone" analysis, to find the source of problems quickly. The course places a heavy emphasis on "Precision Maintenance" standards—ensuring that alignment, balancing, and torque specifications are met during every repair to extend the life of the asset beyond its original state.

Coverage includes the analysis of "Repeat Failures" and the implementation of a "Failure Reporting, Analysis, and Corrective Action System" (FRACAS). Attendees will explore how to document repairs effectively in the CMMS to provide the data needed for long term reliability improvement. By the end of this course, participants will be able to lead their teams through the high pressure environment of corrective work while maintaining a focus on quality, safety, and the permanent elimination of recurring defects.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Implement a systematic 7-step approach to industrial troubleshooting.
• Differentiate between "Symptoms" and "Root Causes" during a breakdown.
• Apply precision repair techniques to eliminate "Infant Mortality" failures.
• Utilize the "Five Whys" and "Fishbone" diagrams for quick failure analysis.
• Establish quality standards for common repairs (Bearings, Seals, Alignment).
• Identify and eliminate the sources of "Chronic" repeat failures.
• Develop detailed "Standard Operating Procedures" (SOPs) for critical repairs.
• Use the CMMS to track "Failure Codes" and "Cause Codes" accurately.
• Conduct "Post-Repair" audits to ensure work quality and compliance.
• Implement a formal "FRACAS" workflow within the maintenance team.
• Manage the "Emergency Work" process without compromising safety.
• Train junior technicians in logical troubleshooting and precision skills.

TARGET AUDIENCE:

This course is vital for Maintenance Supervisors, Lead Technicians, Maintenance Engineers, Reliability Coordinators, and Workshop Managers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.