Day 1:
Foundations of Maintenance Planning and Reliability
Introduction to maintenance planning principles and their role in operational excellence.
Overview of Reliability-Centered Maintenance (RCM) and its core components.
Key metrics and KPIs for measuring maintenance effectiveness.
Case study: Lessons learned from a successful RCM implementation in the aviation industry.
Day 2:
Total Productive Maintenance (TPM) and Collaborative Practices
Principles and benefits of TPM in enhancing equipment efficiency.
Strategies for fostering cross-functional collaboration between maintenance and operations teams.
Tools for conducting root cause analysis and addressing recurring issues.
Group exercise: Developing a TPM roadmap for a hypothetical manufacturing facility.
Day 3:
Risk Management and Failure Analysis
Fundamentals of Failure Mode and Effects Analysis (FMEA).
Identifying and prioritizing critical failure modes in complex systems.
Techniques for mitigating risks through preventive and predictive measures.
Real-world example: How FMEA reduced downtime in a chemical processing plant.
Day 4:
Predictive Maintenance and Emerging Technologies
Introduction to predictive maintenance and its alignment with Industry 4.0.
Leveraging IoT sensors and data analytics for condition monitoring.
Best practices for integrating predictive tools into existing maintenance workflows.
Interactive session: Building a predictive maintenance pilot project.
Day 5:
Sustainability, Change Management, and Implementation
The role of maintenance strategies in achieving sustainability objectives.
Developing a change management plan to overcome resistance to new methodologies.
Steps for rolling out a comprehensive maintenance and reliability program.
Final workshop: Presenting group projects and receiving expert feedback.
