Course Overview

High reliability and effective maintenance are essential for achieving operational excellence, improving asset availability, and controlling life-cycle costs. Ineffective maintenance practices can result in recurring failures, unplanned downtime, increased safety risks, and excessive operating expenses. Adopting reliability-based maintenance strategies is therefore critical for asset-intensive industries seeking sustainable performance improvements.

The Maintenance and Reliability Best Practices programme by TransforMentors Academy provides participants with practical knowledge and proven methodologies for enhancing asset reliability and optimising maintenance performance. The course covers maintenance planning and scheduling, reliability-centred maintenance (RCM), Total Productive Maintenance (TPM), Failure Reporting, Analysis, and Corrective Action Systems (FRACAS), reliability analytics, and continuous improvement strategies.

Through practical exercises, real-world case studies, and interactive discussions, participants will explore structured maintenance frameworks, root cause analysis, failure prevention techniques, asset performance measurement, and data-driven decision-making tools. The programme also examines best practices for integrating maintenance and reliability initiatives with broader asset management and operational objectives.

Agenda

Day — 1 Asset Cost Management Introduction

• Understanding the fundamental concepts of reliability, maintenance, and asset management
• Exploring the factors that influence total maintenance cost throughout an asset’s life cycle
• Identifying industry best practices for maintenance and reliability management
• Understanding the key elements of effective asset management frameworks
• Reviewing methods for measuring maintenance and reliability performance
• Exploring the principles of TPM, RCM, BCM, QCM, and other asset management approaches
• Exercise: Open discussion session to relate maintenance and reliability concepts to participants’ work environments

Day — 2 Laying the Groundwork

• Understanding the importance of collaboration between maintenance, operations, and stores in improving asset reliability
• Exploring the application and benefits of key asset management standards:
  • PAS 55
  • JA1011
• Understanding organisational expectations for implementing effective asset management systems
• Defining and measuring asset performance requirements and reliability targets
• Exploring the different forms of asset failure and degradation in practical settings
• Identifying the causes and mechanisms of asset failure and deterioration
• Evaluating the operational, financial, and risk impacts of asset degradation
• Exercise: Assess common asset failure scenarios and identify their causes, consequences, and mitigation strategies

Day — 3 Applying the Value-Based Process

• Understanding methods for breaking the cycle of repeated failures and asset degradation
• Applying preventive maintenance (PM) tactics based on cost and risk analysis
• Determining optimal preventive maintenance intervals to balance reliability and cost
• Exploring condition-based maintenance (CBM) techniques using the PF-curve for maintenance planning
• Understanding the four essential reliability functions within maintenance programmes
• Optimising spare parts inventory to support effective maintenance operations
• Justifying maintenance programme decisions using cost, risk, and reliability considerations
• Exercise: Develop a value-based maintenance strategy for a critical asset using cost and risk analysis

Day — 4 Ensuring the Continuity of the Value-Based Process

• Applying the PLAN, DO, REVIEW continuous improvement cycle using FRACAS
• Understanding the principles and requirements of a Failure Reporting, Analysis, and Corrective Action System (FRACAS)
• Structuring and coding maintenance data to support effective reliability analysis
• Applying Pareto analysis and data stratification to prioritise improvement opportunities
• Identifying asset life-cycle losses to support cost-effective maintenance decisions
• Developing and verifying root cause hypotheses using evidence-based failure analysis techniques
• Exploring software tools and templates that support reliability and continuous improvement programmes
• Exercise: Analyse a failure scenario using FRACAS and develop corrective actions based on reliability data

Day — 5 Supporting Processes that Lower Life-Cycle Costs

• Applying best practices for planning and scheduling maintenance activities
• Optimising manpower and skills deployment to achieve cost-effective maintenance performance
• Identifying and using key performance indicators (KPIs) to support continuous improvement
• Exploring practical methods for embedding reliability and maintenance best practices into daily operations
• Aligning maintenance processes with long-term asset performance and life-cycle cost objectives
• Exercise: Develop an action plan to improve maintenance efficiency and reliability within your organisation
• Key takeaways and course evaluation

Learning Outcomes

By attending the Maintenance and Reliability Best Practices course, you will be able to:

• Understand and apply the principles of reliability, maintenance, and asset management to improve operational performance
• Analyse maintenance costs to identify opportunities for reducing asset life-cycle expenses
• Implement value-based maintenance strategies, including preventive and condition-based maintenance practices
• Apply structured reliability tools and data analysis techniques to identify and eliminate chronic failures
• Improve maintenance planning, scheduling, and resource utilisation to support reliability-centred maintenance (RCM)
• Develop practical action plans to embed continuous improvement and maintenance best practices across their organisations

Who Should Attend

The Maintenance and Reliability Best Practices course is ideal for professionals responsible for asset performance and maintenance excellence. It is especially beneficial for:

• Maintenance and Reliability Engineers
• Asset and Plant Managers
• Operations and Engineering Supervisors
• Maintenance Planners and Coordinators
• Continuous Improvement Specialists
• Maintenance and Asset Management Professionals
• Reliability and Asset Integrity Engineers
• Production and Operations Managers
• Facilities and Engineering Managers