Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Maintenance and Reliability Engineers
• Maintenance Supervisors and Planners
• Operations and Production Personnel
• Plant Engineers and Asset Management Professionals
• Engineering Technicians and Maintenance Staff
• Anyone responsible for maintenance strategy, planning, or equipment care

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand preventive and predictive maintenance concepts and differences
• Develop structured preventive maintenance programs
• Apply condition monitoring techniques in predictive maintenance
• Identify failure modes and select the right maintenance strategy
• Optimize maintenance activities for cost, reliability, and safety
• Measure maintenance performance using KPIs and reliability metrics

DAY 1

Foundations of Preventive and Predictive Maintenance

• Maintenance management fundamentals and the role of maintenance in asset reliability and operational performance 
• Evolution from reactive to proactive maintenance strategies 
• Corrective, preventive, predictive, condition-based, and reliability-centered maintenance 
• Reliability, availability, and maintainability principles 
• Equipment failure patterns, failure modes, mechanisms, and consequences 
• The P-F Curve and failure development process 
• Maintenance audits, equipment criticality analysis, and asset classification 
• Establishing equipment condition baselines and identifying maintenance improvement opportunities 
• Preventive maintenance programs, time-based and usage-based maintenance 
• Developing effective PM tasks, procedures, checklists, work orders, and maintenance records
   

DAY 2

Predictive Maintenance and Condition Monitoring Technologies

• Preventive maintenance optimization and determination of effective maintenance intervals 
• Planned component replacement and elimination of unnecessary maintenance activities 
• Predictive maintenance concepts, benefits, and applications 
• Differences between preventive, predictive, and condition-based maintenance 
• Predictive maintenance implementation and equipment suitability assessment 
• Condition monitoring principles, data collection, trending, and early fault detection 
• Vibration analysis, monitoring technologies, fault identification, and trend interpretation 
• Lubrication monitoring, oil analysis, contamination detection, and wear assessment 
• Infrared thermography for electrical and mechanical fault detection 
• Ultrasonic testing, shock pulse monitoring, motor current analysis, NDT, smart sensors, and predictive data analysis
   

DAY 3

Preventive and Predictive Maintenance Planning, Integration, and Performance Optimization

• Planning and scheduling preventive maintenance activities 
• PM frequency determination, resource planning, and maintenance work management 
• Organizing and implementing predictive maintenance programs 
• Integrating preventive and predictive maintenance into existing maintenance systems 
• Combining PM and PdM with condition-based, reliability-centered, and risk-based maintenance 
• Maintenance KPIs, PM/PdM effectiveness, downtime analysis, and performance trending 
• Maintenance cost analysis, benchmarking, and return on investment 
• CMMS, maintenance databases, spare parts forecasting, and inventory management 
• Maintenance reporting, dashboards, and equipment performance monitoring 
• Continuous improvement, TPM integration, long-term maintenance roadmaps, and management support