COURSE OVERVIEW:

The core meaning of this course is the orchestration of the three primary maintenance tactics into a unified, risk-based strategy. Most maintenance departments operate in silos, where "Preventive" tasks are performed regardless of "Predictive" findings, leading to over-maintenance or unexpected failures. This course focuses on the "Integrated Maintenance Model," where the selection of the maintenance tactic is determined by the specific failure mode of the asset and its criticality to the business.

The scope of this training involves the technical application of Preventive (time-based), Predictive (condition-based), and Corrective (run-to-fail) maintenance. Participants will examine how to build a "Maintenance Strategy Matrix" that aligns these tactics with the "P-F Interval" (Potential to Functional failure). The curriculum emphasizes the dynamic nature of an integrated strategy, where condition monitoring data is used to extend or shorten time-based intervals, thereby optimizing both labor and material costs.

Coverage includes the development of "Standard Job Plans" for all three tactics, the use of "Failure Mode and Effects Analysis" (FMEA) for strategy selection, and the integration of these tasks within the CMMS. Attendees will explore the "Economics of Maintenance," comparing the cost of a proactive intervention against the total cost of a corrective repair. By the end of this course, participants will be able to design a balanced maintenance program that eliminates "Non-Value Added" work while maximizing the reliability and life expectancy of plant equipment.

COURSE OBJECTIVES:

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

• Define the technical characteristics of Preventive, Predictive, and Corrective maintenance.
• Map maintenance tactics to specific "Failure Modes" using FMEA.
• Utilize the "P-F Interval" to determine optimal Condition Monitoring frequencies.
• Identify the "Hidden Costs" of an unplanned Corrective maintenance event.
• Optimize "Preventive Maintenance" (PM) intervals using historical data.
• Integrate Vibration, Oil Analysis, and Ultrasound into a "Predictive" program.
• Develop "Standard Operating Procedures" (SOPs) for integrated work.
• Calculate the "Total Cost of Ownership" (TCO) for different maintenance strategies.
• Use "Reliability Centered Maintenance" (RCM) logic for tactic selection.
• Manage the "Work Order" flow for proactive vs. reactive tasks in the CMMS.
• Transition from "Time-Based" to "Condition-Based" maintenance for critical assets.
• Measure the "ROI" of the integrated maintenance strategy.

TARGET AUDIENCE:

This course is essential for Maintenance Planners, Reliability Engineers, Maintenance Supervisors, Asset Analysts, and Production Coordinators.

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.