• Maintenance and Reliability Professionals
• Production/Operations Professionals
• Senior Engineering, Maintenance, and Reliability Managers

Day 1
Manufacturing Process Reliability

This subject area relates maintenance and reliability activities to the manufacturing process of the organization to ensure that maintenance and reliability activities improve the manufacturing process.

1.1 Understand the applicable processes

• Document process flow
• Understand process parameters
• Understand quality specifications

1.2 Apply process improvement techniques

• Identify production losses
• Establish a continuous improvement process

1.3 Manage the effects of the change to processes and equipment

• Establish change protocol
• Update documentation
• Update procedures

1.4 Maintain processes in accordance with applicable standards and regulations

• Understand industry standards
• Understand regulatory requirements
• Ensure compliance

Day 2
Equipment Reliability
This subject area describes two kinds of activities that apply to the equipment and processes for which the maintenance and reliability professional is accountable. First, are those activities used to assess the current capabilities of the equipment and processes in terms of their reliability, availability, maintainability, and criticality? Second, are the activities used to select and apply the most appropriate maintenance practices, so that the equipment and processes continue to deliver their intended capabilities in the safest and most cost-effective manner.

2.1 Determine equipment reliability expectations

• Identify reliability goals
• Identify process expectations

2.2 Evaluate equipment reliability and identify improvement opportunities

• Measure and track performance
• Determine best-demonstrated performance
• Analyze gaps

2.3 Establish a strategic plan to assure the reliability of existing equipment

• Identify appropriate analysis techniques
• Develop maintenance strategy and tactics

2.4 Establish a strategic plan to assure the reliability of new equipment

• Establish reliability specifications
• Establish acceptance criteria
• Obtain complete documentation

2.5 Cost-justify selected plans for implementation

• Conduct cost-benefit analysis
• Communicate benefits
• Obtain approval

2.6 Implement selected plans to assure equipment reliability

• Apply reliability strategies
• Establish organization structure
• Provide resources

2.7 Review the reliability of equipment and adjust the reliability strategy

• Assess key performance indicators
• Analysis deviations
• Identify relevant best practices
• Implement continuous improvement
• Case Study/Exercise: Develop a criticality structure, and conduct criticality ranking.

Day 3
Work Management
This subject area focuses on the skills used to get the maintenance and reliability work done. It includes planning and scheduling activities, quality assurance of maintenance activities, stores, and inventory management.

3.1 Identify, validate, and approve work

• Establish work identification processes
• Select and approve viable work

3.2 Prioritize work

• Develop a formal prioritizing system
• Implement a formal prioritizing system

3.3 Plan work

• Develop job package
• Including scope and procedures
• Including materials and tools
• Including testing

3.4 Schedule work

• Develop scheduling process
• Produce work schedule
• Balance resources
• Monitor backlog
• Manage break-in work

3.5 Execute work

• Manage labor
• Manage material and services
• Control Productivity
• Ensure EHS compliance

3.6 Document work

• Create post work document process
• Record failure events and failure modes

3.7 Analyze work and follow-up

• Compare actual work with a plan
• Identify variances

3.8 Measure work management performance

• Establish performance indicators
• Report schedule compliance and rework

3.9 Plan and execute projects

• Define scope
• Estimate project and life cycle costs
• Apply critical path methods
• Track progress
• Coordinate staffing

3.10 Use information technologies effectively

• Leverage capabilities of data historian
• Process control systems
• Condition monitoring software
• EAM, CMMS systems functionality

3.11 Manage resources and materials

• Control materials inventory
• Manage spares and equipment
• Establish the MRO procurement process
• Manage contractors
• Reliability Centered Maintenance
• Failure Mode Effects Analysis
• Criticality Analysis
• Pm Optimization
• Root Cause Analysis
• Reliability Engineering
• Capital Project Management
• Vibration Analysis
• Ultrasound Testing
• Alignment and Balancing
• Motor Testing
• Machinery Lubrication
• Case Study/Exercise: Conducting FMEA study followed by criticality-based task selection
• Non Destructive Testing
• Infrared Thermal Imaging
• Asset Condition Information
• Oil Analysis
• Preventive Maintenance
• Planning and Scheduling
• Operator Driven Reliability
• MRO Spares Management
• Defect Elimination
• Computerized Maintenance Management
• Systems (CMMS)
• Operational Excellence
• Key Performance Indicators
• Physical Asset Management
• Human Capital Management
• Integrity
• Competency-Based Learning
• Executive Sponsorship

Day 4
This subject area describes processes for assuring that the maintenance and reliability staff is the most qualified and best assigned to achieve the maintenance and reliability organization goals.

4.1 Determine organizational requirements

• Review strategic plan
• Determine required skills
• Determine required staffing levels

4.2 Analyze organizational capability

• Inventory staff skills
• Determine performance gaps

4.3 Develop the organizational structure

• Establish reporting channels
• Determine roles
• Determine responsibilities
• Manage reorganization

4.4 Develop personnel

• Provide training
• Obtain needed expertise
• Delineate career paths

4.5 Lead and manage people

• Develop leadership skills
• Assess performance
• Promote a cooperative work environment
• Facilitate communication
• Case Study/Exercise: Developing the appropriate management structure to assign and manage these tasks as well as follow up and track

Day 5
Business and Management
This subject area describes the skills used to translate an organization’s business goals into appropriate maintenance and reliability goals that support and contribute to the organization’s business results.

5.1 Create Strategic direction and plan for M&R operations

• Provide vision and direction
• Provide clear and measurable goals

5.2 Administer Strategic plan

• Develop support
• Obtain approval and resources
• Implement plans

5.3 Measure Performance

• Select key performance indicators
• Track and report

5.4 Manage organizational plan

• Develop a change management process
• Communicate benefits

5.5 Communicate with stakeholders

• Provide management reports
• Inform staff
• Coordinate with operations

5.6 Manage environmental-health-safety risk

• Support community EHS goals
• Support security goals
• Conform to applicable regulations
• Provide EHS training
• Case Study/Exercise: Performing basic data analytics using exponential and Weibull distributions