COURSE OVERVIEW:

The core meaning of this course is the systematic engineering of time-based and usage-based maintenance tasks to prevent asset failure before it occurs. Many industrial PM programs are "legacy" systems, consisting of redundant or ineffective tasks that waste resources or even induce failure through unnecessary intervention. This course focuses on the "Clean-Sheet" design of a PM program and the subsequent optimization of existing programs to maximize "Value-Add" for every man-hour spent.

The scope of this training involves the transition from simple "Manufacturer Recommendations" to a customized, site-specific PM strategy. Participants will learn how to identify the "Failure Modes" that are truly preventable through time-based action and how to design specific "Task Instructions" that ensure consistent execution across different shifts. The curriculum emphasizes the "PM Optimization" (PMO) process, which uses historical failure data and "Wrench Time" analysis to prune ineffective tasks and refine the frequency of essential ones.

Coverage includes the development of "Standard Job Plans," the management of PM backlogs, and the integration of "Operator Care" (TPM) into the overall preventive strategy. Attendees will explore the "Mathematics of PM," using statistical tools to determine the optimal "Frequency" that balances the risk of failure against the cost of the maintenance intervention. By the end of this course, participants will be able to transform their PM program into a streamlined, high-impact engine for reliability that significantly reduces unplanned downtime and maintenance costs.

COURSE OBJECTIVES:

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

• Define the technical criteria for a "Preventable" failure mode.
• Design a "Clean-Sheet" PM program based on equipment criticality.
• Conduct a "PM Optimization" (PMO) review of an existing program.
• Identify and eliminate "Non-Value Added" (NVA) maintenance tasks.
• Write clear, unambiguous "Job Plans" with specific acceptance criteria.
• Calculate the "Optimal PM Frequency" using failure data and cost.
• Differentiate between "Time-Based" and "Usage-Based" (Metered) PMs.
• Integrate "Safety and Environmental" compliance into the PM flow.
• Manage the "PM Backlog" and measure "PM Compliance" accurately.
• Implement "Operator Care" (TPM) for basic preventive activities.
• Utilize the "Five Senses" for effective preventive inspections.
• Use CMMS data to prove the "Return on Investment" of the PM program.

TARGET AUDIENCE:

This course is essential for Maintenance Planners, Reliability Engineers, Maintenance Supervisors, CMMS Administrators, and Technical Writers.

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.