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In today’s competitive industrial landscape, effective maintenance planning is crucial for ensuring asset reliability, minimizing downtime, and optimizing operational efficiency. Advanced Maintenance Planning goes beyond basic maintenance strategies by integrating modern technologies, data-driven decision-making, and risk-based methodologies to enhance asset performance and cost-effectiveness.

This course provides participants with in-depth knowledge of maintenance strategies, including Reliability-Centered Maintenance (RCM), Predictive Maintenance (PdM), Total Productive Maintenance (TPM), and Condition-Based Monitoring (CBM). It also covers budgeting, risk assessment, and digital transformation in maintenance to align with global best practices.

Advanced Maintenance Planning objectives:

By the end of this course, participants will:

•  Develop advanced maintenance strategies to enhance asset performance.
•  Implement Reliability-Centered Maintenance (RCM) and Total Productive Maintenance (TPM).
•  Optimize maintenance schedules using Predictive and Preventive Maintenance (PdM & PM).
•  Utilize maintenance KPIs and performance measurement tools.
•  Integrate AI, IoT, and data analytics for smart maintenance solutions.
•  Reduce maintenance costs while improving efficiency and reliability.
•  Apply risk-based maintenance planning to ensure long-term asset sustainability.

Who Should Attend:

This course is ideal for:

• Maintenance Managers and Engineers.
• Asset Management Professionals.
• Facility Managers and Operations Supervisors.
• Reliability and Maintenance Planners.
• Project Engineers and Technicians.
• Industrial, Manufacturing, and Oil & Gas Professionals.
• Anyone responsible for optimizing maintenance operations.

Course Outline

Day 1: Foundations of Advanced Maintenance Planning

• Overview of modern maintenance strategies.
• Understanding asset lifecycle and total cost of ownership (TCO).
• Types of maintenance: Proactive, Predictive, Preventive, and Reactive.
• The role of maintenance in business profitability.
• Case study: Comparing traditional vs. advanced maintenance planning.

Day 2: Reliability-Centered Maintenance (RCM) & Asset Performance Management

• Principles and applications of Reliability-Centered Maintenance (RCM).
• Failure Mode and Effects Analysis (FMEA) for maintenance optimization.
• Asset performance management (APM) and risk assessment.
• Implementing RCM in different industries.
• Workshop: Conducting a real-world FMEA analysis.

Day 3: Predictive & Preventive Maintenance Strategies

• Developing a Predictive Maintenance (PdM) framework.
• Condition-Based Monitoring (CBM) techniques: Vibration, Thermography, Oil Analysis.
• AI and Machine Learning in Predictive Maintenance.
• Building an optimized Preventive Maintenance (PM) plan.
• Workshop: Creating a predictive maintenance model.

Day 4: Total Productive Maintenance (TPM) & Lean Maintenance

• The pillars of Total Productive Maintenance (TPM).
• Reducing downtime with Autonomous Maintenance.
• Implementing TPM in manufacturing and industrial settings.
• Lean Maintenance principles for process efficiency.
• Case study: Successful TPM implementation.

Day 5: Maintenance Budgeting, Cost Control & Performance Metrics

• Budgeting strategies for maintenance operations.
• Cost-benefit analysis for maintenance investments.
• Tracking maintenance KPIs: MTBF, MTTR, OEE, and downtime costs.
• Benchmarking maintenance performance.
• Workshop: Analyzing maintenance cost data.

Day 6: Digitalization & Smart Maintenance Technologies

• The role of Industry 4.0 in maintenance planning.
• IoT, AI, and Big Data for asset management.
• CMMS (Computerized Maintenance Management Systems) and ERP integration.
• Remote monitoring and predictive analytics in maintenance.
• Case study: How digital transformation is reshaping maintenance strategies.

Day 7: Shutdown, Turnaround & Outage (STO) Planning

• Planning and managing maintenance shutdowns.
• Shutdown risk assessment and contingency planning.
• Resource allocation and team coordination for effective execution.
• Ensuring safety and compliance during shutdowns.
• Workshop: Developing a shutdown execution plan.

Day 8: Maintenance Outsourcing & Vendor Management

• Evaluating the need for maintenance outsourcing.
• Selecting and managing external maintenance service providers.
• Defining SLAs and monitoring contractor performance.
• Integrating outsourced services into existing maintenance strategies.
• Case study: Best practices in outsourcing maintenance services.

Day 9: Risk-Based Maintenance & Sustainability in Maintenance

• Implementing Risk-Based Maintenance (RBM) methodologies.
• Business continuity planning for maintenance disruptions.
• Sustainable maintenance practices and environmental considerations.
• Developing a long-term maintenance strategy for organizational resilience.
• Workshop: Creating a sustainability-focused maintenance plan.

Day 10: Final Assessment & Certification

• Capstone project: Designing a comprehensive advanced maintenance plan.
• Final assessment and expert feedback session.
• Certification ceremony.
• Q&A and course wrap-up.