Fundamentals of Maintenance Management

Introduction – The Maintenance Challenge

This module gives context to the course in terms of the global problem of ageing assets, terms and definitions, and the objectives of maintenance, using the Maintenance Management model as the driver.

Measuring and Managing Performance

This module introduces the PDCA cycle and the need for performance measurement. Key concepts are defined and a framework provided for a balanced maintenance scorecard. Finally, the role of daily meetings to review performance and drive improvements is discussed.

Asset Reliability

This module defines asset reliability and the role of
the reliability engineer. The different failure profiles
(age- related vs random), the P-F curve and the impact
of forced deterioration are unpacked. The calculation
and interpretation of MTBF is reviewed using
appropriate examples.

Maintenance Tactics

This module explains how asset criticality is defined and where it is applied. The four basic maintenance tactics are explained, how they are selected based on the components’ failure profiles, their packaging and implementation in the information system.

Maintenance Work Management

This module covers the 9-step process to manage maintenance work – the approval, planning, scheduling, allocation and execution of work. The roles of the people involved, the underlying best practices and the KPIs to measure the success of the process are explained using appropriate examples.

Material and Tools Management

This module gives learners insight into the Supply Chain processes and the effect on Maintenance and how certain bad maintenance practices (like squirrel stores) impact the effectiveness of material management.

Contractor Management

This module introduces some basic principles about making an outsourcing decision, selecting contractors  and managing them as “external employees” according to the type of contract.

Operate for Reliability

This module covers the role of operational staff in asset reliability and performance improvement, by doing basic maintenance tasks like cleaning, inspections, minor repairs and assisting artisans with major work.

Roles, Structures and Competencies

This module gives an overview of a Maintenance structure and responsibilities. It covers all the important concepts related to training including competencies and assessment.

Asset Data and Information Management

This module explains the functionality of a typical maintenance information system. It covers the data management process for effective information, and how to manage changes to ensure up-to-date documentation.

Strategic Plans and Budgets

This module covers the strategic planning process – the development of an end-state maintenance vision, a 3-pronged gap assessment, and the development of a prioritised improvement strategy, with supporting budget.