COURSE OVERVIEW:

The fundamental meaning of this course is the large-scale deployment of RCM principles across an entire industrial facility to create a unified asset strategy. Advanced RCM moves beyond isolated pilot studies to a comprehensive framework that addresses the functional requirements of every critical system in the plant. This course focuses on the "Scaling" of RCM, ensuring that the process is technically rigorous enough to meet SAE JA1011 standards while remaining efficient enough to be applied to thousands of assets.

The scope of this training involves the strategic management of RCM "Study Groups," the prioritization of systems based on a master criticality matrix, and the technical integration of results into the enterprise resource planning (ERP) system. Participants will explore advanced failure mode modeling, focusing on "Hidden Failures" and complex "Protection Loops" that are often missed in basic maintenance plans. The curriculum emphasizes the "Implementation" phase, where theoretical tasks are transformed into executable field instructions.

Coverage includes the development of "Standard Job Plans," the calculation of "Failure Finding Task" intervals, and the use of "Reliability Dashboards" to monitor the success of the RCM program. Attendees will examine how to manage the "Legacy Data" challenge and how to foster a culture where RCM is a "Living Program" rather than a one-time event. By the end of this program, participants will be able to architect and lead an enterprise-wide RCM deployment that delivers measurable improvements in plant availability and risk reduction.

COURSE OBJECTIVES:

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

• Define the technical requirements for an "SAE JA1011 Compliant" RCM program.
• Develop a "Master System Hierarchy" for plant-wide RCM deployment.
• Prioritize plant systems for RCM using a "Risk-Based" scoring model.
• Facilitate multidisciplinary "RCM Analysis Teams" in a high-velocity environment.
• Master the "7 Questions" of RCM for complex, interconnected process units.
• Design "Failure Finding Tasks" for protective systems using probabilistic modeling.
• Map "Failure Consequences" to specific safety, environmental, and economic risks.
• Utilize the "RCM Decision Logic" to justify proactive maintenance vs. redesign.
• Integrate RCM outputs directly into the "CMMS/ERP" work management cycle.
• Manage "Hidden Failure" risks through standardized functional testing.
• Audit the "Technical Quality" of RCM studies to ensure engineering integrity.
• Demonstrate the "Business Value" of RCM through OEE and cost-per-ton metrics.

TARGET AUDIENCE:

This course is designed for Reliability Managers, Maintenance Directors, Asset Engineers, RCM Facilitators, and Senior Operations 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.