COURSE OVERVIEW:

The sustainability of industrial operations depends on the functional integrity of a vast array of mechanical assets, ranging from static piping to complex rotating machinery. This course provides a technical deep dive into the Reliability-Centred Maintenance (RCM) methodology, specifically tailored for the mechanical discipline. Participants will explore the rigorous process of defining what an asset must do in its operating context and establishing the most effective maintenance tasks to prevent functional failure.

The scope of this training encompasses the technical analysis of failure modes and their physical effects on mechanical systems. We will move beyond traditional "one-size-fits-all" maintenance manuals to develop strategies based on the actual failure characteristics of the equipment, such as wear-out, fatigue, and random failure patterns. The course emphasizes the importance of understanding the "hidden" failure modes of protective devices and the critical role of the P-F interval in determining the frequency of condition-based inspections.

Coverage includes the practical application of RCM logic to prioritize maintenance efforts where they provide the greatest return on safety, environmental protection, and operational availability. Attendees will learn how to facilitate cross-functional RCM workshops and translate the findings into actionable preventive maintenance programs. By mastering RCM for mechanical assets, participants will be equipped to optimize maintenance spend, extend equipment life, and foster a proactive culture of mechanical excellence.

COURSE OBJECTIVES:

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

• Define the fundamental principles of RCM as applied to mechanical systems.
• Identify the operating context and primary functions of mechanical assets.
• Analyze functional failures and their impact on process continuity.
• Document detailed failure modes for gears, bearings, and structures.
• Evaluate the physical and economic consequences of mechanical failures.
• Utilize the RCM decision logic to select the most appropriate task type.
• Distinguish between proactive maintenance and default actions.
• Determine optimal task intervals using P-F interval calculations.
• Develop specialized maintenance strategies for static and pressurized assets.
• Identify hidden failure modes in mechanical safety and standby systems.
• Integrate RCM strategies into existing Asset Management frameworks.
• Lead a team through a comprehensive RCM analysis of a critical subsystem.
• Justify the transition from time-based to condition-based maintenance.
• Measure the effectiveness of RCM implementation through reliability KPIs.

TARGET AUDIENCE:

Mechanical Engineers, Maintenance Superintendents, Asset Integrity Specialists, Reliability Engineers, and Technical Leads responsible for mechanical plant infrastructure.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.