Our Maintenance and Reliability Training Program is designed to help organizations improve asset availability, reduce downtime, optimize maintenance costs, and enhance operational safety. The training combines engineering theory, practical examples, and real plant case studies.
Training Objectives
- Improve equipment reliability and lifecycle performance
- Reduce unplanned failures and maintenance costs
- Apply reliability engineering tools for decision-making
- Develop effective preventive and predictive maintenance strategies
- Enhance maintenance planning, execution, and documentation
Core Training Modules
1. Fundamentals of Maintenance & Reliability
- Maintenance vs Reliability Engineering
- Asset Lifecycle Management
- Reliability-Centered Maintenance (RCM) Overview
- Maintenance Strategies: Run-to-Failure, Preventive, Predictive & Proactive
- KPIs: Availability, Reliability, Maintainability
2. Reliability Metrics & Analysis
- Mean Time To Failure (MTTF)
- Mean Time Between Failures (MTBF)
- Mean Time To Repair (MTTR)
- Failure Rate (λ) and Reliability Functions
- Equipment Availability Calculations
- Practical Examples using Plant Data
3. Reliability-Centered Maintenance (RCM)
- RCM Principles & Methodology
- Functional Failure Analysis
- Failure Modes & Effects Analysis (FMEA)
- Failure Effects & Consequence Classification
- Selection of Maintenance Tasks
- RCM Decision Logic & Task Intervals
- RCM Implementation in Brownfield & Operating Plants
4. Failure Modes & Effects Analysis (FMEA)
- FMEA Concepts & Terminology
- Equipment Functional Breakdown
- Identification of Failure Modes & Causes
- Severity, Occurrence & Detection Ranking
- Risk Priority Number (RPN) Calculation
- Development of Maintenance Actions
- FMEA Documentation & Reporting
5. Preventive Maintenance (PM)
- Preventive Maintenance Philosophy
- Time-Based vs Condition-Based Maintenance
- PM Task Development & Optimization
- Equipment-Specific PM Programs:
- Pumps, Compressors, Motors
- Valves & Actuators
- Electrical Panels & Switchgear
- Instruments & Control Systems
- PM Scheduling & Work Order Management
- PM Checklists & Standard Job Plans
6. Predictive Maintenance (PdM)
- Predictive Maintenance Concepts
- Condition Monitoring Techniques:
- Vibration Analysis
- Thermography
- Oil Analysis
- Ultrasound Testing
- Motor Current Signature Analysis (MCSA)
- Predictive Maintenance Data Interpretation
- Alarm Limits & Trend Analysis
- Integration with CMMS / EAM Systems
7. Maintenance Planning & Documentation
- Maintenance Strategy Selection
- Maintenance Task Lists & Job Plans
- Spare Parts Optimization & Criticality Analysis
- Maintenance Documentation & Records
- CMMS / SAP PM Basics
- Maintenance KPIs & Performance Monitoring
8. Practical Case Studies & Workshops
- MTBF / MTTF Calculation from Plant History
- FMEA Workshop for Critical Equipment
- RCM Study for Rotating Equipment
- Preventive vs Predictive Maintenance Comparison
- Maintenance Optimization Case Studies
Training Deliverables
- Training Presentations & Study Materials
- Calculation Templates (MTBF, MTTF, Availability)
- Sample FMEA & RCM Worksheets
- Preventive Maintenance Checklists
- Case Study Examples
- Certificate of Completion
Target Audience
- Maintenance Engineers & Supervisors
- Reliability Engineers
- Electrical & Instrumentation Engineers
- Mechanical Engineers
- Operations & Asset Management Teams
Training Mode
- Classroom Training
- Online / Virtual Sessions
- Corporate / On-Site Training
- Customized Programs as per Client Assets