Introduction

Effective maintenance and asset management are essential to achieving reliable operations, controlling costs, improving productivity, and extending the life of critical assets. Organizations need more than routine maintenance activities. They require a well-planned strategy that aligns maintenance decisions with business objectives, operational requirements, safety standards, and long-term asset performance.

This course provides participants with practical knowledge and strategies for developing successful maintenance programmes, managing asset performance, reducing unnecessary costs, improving reliability, and integrating maintenance with overall business objectives. It also explores modern approaches to maintenance planning, reliability improvement, risk management, performance measurement, and shutdown management.

Course Outline

Module 1: Total Cost of Maintenance and Maintenance Strategy

• Understanding total maintenance cost, fixed costs and cost drivers
• Maintenance benchmarking, best practices and value creation
• Cost of lost production and non-compliance
• Developing a modern, cost-effective maintenance strategy
• Maintenance planning, spending priorities and asset management
• Integrating cost reduction, reliability and safety

Module 2: Fixed Cost Reduction, Waste Elimination and Supply Chain Management

• Maintenance cost analysis, mapping and root-cause identification
• Developing cost reduction programmes and performance KPIs
• Eliminating maintenance waste and improving work efficiency
• Risk-based, planned and preventive maintenance
• Improving maintenance methods, productivity and standards
• Managing contractors, spare parts, materials and supply chain costs

Module 3: Plant Performance, Reliability and Cost-Effective HSE

• Plant performance and reliability improvement
• Reliability roadmaps and models of maintenance excellence
• Selecting appropriate maintenance strategies and improving asset life
• Overall Equipment Effectiveness (OEE) and maintenance performance measures
• Integrating operations and maintenance for improved performance
• Cost-effective HSE, risk-based inspection and regulatory compliance

Module 4: Shutdown Management and Maintenance Excellence

• Principles and importance of effective shutdown management
• Model of excellence and critical success factors
• Shutdown strategy, front-end loading and structured work processes
• Shutdown organization, safety and quality control
• Planning, logistics, execution and post-shutdown review
• Shutdown economics, forecasting, cost control and performance improvement

Conclusion

A successful maintenance strategy requires a balanced approach that considers cost, reliability, safety, asset performance, and business objectives. By applying effective maintenance planning, reliability improvement techniques, cost-control strategies, asset management principles, and structured shutdown processes, organizations can reduce waste while improving operational performance.