Maintenance Management: Developing and Enhancing Strategies (10 Days)

Introduction

In the volatile and competitive landscape of process plant operations, the importance of a robust maintenance management strategy is often underestimated. This Maintenance Management Strategy and Process program focuses on enhancing core competencies such as work planning, scheduling, and work control. Participants will learn to integrate advanced tools like maintenance auditing and benchmarking to maintain consistency, drive improvements, identify best practices, and strategically develop maintenance management systems.

Objectives

By the end of the Certified Maintenance Manager Certification Course, participants will be able to:

• Identify and address gaps in planning practices and critical elements.
• Resolve common planning issues using techniques from leading organizations.
• Benchmark their practices against industry standards.
• Improve the use of information and communication tools.
• Enhance productivity through timely and accurate information.
• Optimize work management lead times for better resource planning and scheduling.
• Ensure consistent and reliable management of asset information.
• Execute maintenance turnovers more efficiently.
• Refine preventive and predictive maintenance strategies.
• Conduct thorough maintenance audits.
• Perform benchmarking studies to guide improvement strategies.
• Develop and implement improvement plans based on benchmarking results.

Training Methodology

• Interactive Workshops
• Case Studies
• Role-Playing Exercises
• Simulation Scenarios
• Group Discussions
• Expert Guest Lectures
• Benchmarking Exercises

Course Outline

Unit 1: Modern Maintenance Management Practice in Perspective

• Equipment listing and classification
• Maintenance practice overview
• Maintenance as a business process
• Evolution of maintenance management practices
• Maintenance’s role in achieving organizational goals
• Development of maintenance strategy
• Key performance indicators (KPIs) for business, operations, and maintenance
• Responsibilities and accountability
• CMMS considerations
• Equipment identification and documentation

Unit 2: Maintenance Policies and Logistics Planning

• Maintenance management policies
• Equipment criticality grading
• Job record policies and information requirements
• Work order design and priority
• Maintenance logistics planning
• Support analysis and equipment for support
• Organizational and personnel considerations

Unit 3: Development of the Failure Management Programme

• Failure modes and effects analysis (FMEA)
• Equipment functions and performance criteria
• Functional failures and their causes
• Policies for failure management
• Types of failures and their effects
• Condition-based maintenance strategies
• Use of RCM for failure management
• Planning and logistics for maintenance

Unit 4: Work Planning, Scheduling, and Control

• Notification processes and procedures
• Master schedule objectives and creation
• Resource identification and scheduling
• Backlog management
• Maintenance project scheduling and resource allocation

Unit 5: Information and Performance Management

• Management of information and control
• Key performance indicators (KPIs) for maintenance
• Performance measurement by cost and effectiveness
• Management reporting

Unit 6: Introduction and Scope Concepts

• Overview of maintenance management and improvement methods
• Maintenance auditing and benchmarking
• Implementing sustainable improvement approaches

Unit 7: Maintenance Auditing

• Maintenance auditing process and methodology
• Conducting and interpreting maintenance audits
• Using audits for improvement

Unit 8: Maintenance Auditing and Benchmarking

• Internal benchmarking using maintenance audits
• Designing and implementing maintenance benchmarking studies

Unit 9: Maintenance Benchmarking and Performance Measurement

• Benchmarking studies and integration into improvement strategies
• Key performance indicators and the Maintenance Balanced Scorecard

Unit 10: Joining Maintenance Auditing and Benchmarking - Principles and Practice

• Integrating maintenance auditing and benchmarking with performance measurement
• Utilizing measurement results for strategic improvement