Certificate in Maintenance Management

Course overview

Course objectives

Who should attend

Training methodology

Course modules

1. Module 1

   Maintenance strategy formulation and budgeting procedures

   • Classifications and types of maintenance strategies
   • Formulating an overarching departmental maintenance strategy
   • Core financial budgeting fundamentals for engineering managers
   • Building a maintenance operating and capital budget
   • Variance analysis and cost control mechanisms
   • Managing performance through maintenance key performance indicators (KPIs)
2. Module 2

   Reliability Centred Maintenance (RCM) methodology

   • Conducting equipment criticality analysis
   • RCM study methodology and scoping procedures
   • International standards and reference frameworks for RCM
   • Defining functional failures, failure modes and failure effects
   • Developing the RCM decision logic process flow diagram
   • Documenting maintenance task outputs from RCM studies
   • Evaluating tangible operational benefits of RCM programmes
3. Module 3

   Contractor management and outsourcing strategies

   • Defining outsourcing and strategic reasons for third-party support
   • Operational risks and commercial challenges of maintenance outsourcing
   • The maintenance outsourcing lifecycle model
   • Analysing outsourcing strategies and vendor selection criteria
   • Structuring service contracts and managing the procurement process
   • Monitoring contractor safety, performance and contract compliance
4. Module 4

   Planning and scheduling maintenance activities

   • The 6 elements of maintenance planning and scheduling
   • Screening, scoping and prioritising maintenance work requests
   • Formulating a forward maintenance plan
   • Managing the continuous maintenance scheduling cycle
   • Executing work orders and staging required resources
   • Work order close-out and technical completion reporting
   • Post-maintenance review meetings and scheduling continuous improvement
5. Module 5

   Workforce planning, organisation and capability development

   • Key organisational roles and craft positions in maintenance
   • Designing an effective departmental organisational hierarchy
   • Leadership techniques and team motivation in plant environments
   • Workload analysis and task allocation using the RACI matrix
   • Structuring learning and professional development pathways
   • Implementing a Competency Assurance Management System (CAMS)
6. Module 6

   Spare parts inventory control and warehouse management

   • Core operational objectives of spare parts inventory control
   • Primary functions of maintenance materials management
   • Managing the inventory replenishment order cycle
   • Classifying inventory using ABC analysis
   • Calculating stock turnover ratios and stock cover periods
   • Financial methods for inventory valuation
   • Establishing economic reorder points and safety stock policies
   • Targeted initiatives for inventory reduction and warehouse improvement
7. Module 7

   Computerized Maintenance Management System (CMMS) operations

   • Processing initial maintenance work requests
   • The work request screening and approval workflow
   • Classifications of maintenance work requests
   • How formal work requests improve work capture and priority control
   • Authoring detailed maintenance work orders
   • The work order execution and status workflow
   • Classifications of work orders including corrective and preventive tasks
   • Structuring an equipment Bill of Materials (BOM)
   • Core components and data fields within a Bill of Materials
   • Defining the Application Parts List (APL)
   • Technical distinctions between an APL and a BOM
   • Key components and item data in an Application Parts List
   • Conducting hands-on CMMS software workflow simulations
8. Module 8

   Maintenance risk management, safety and compliance

   • Key risk concepts and risk management terminology
   • The strategic importance of risk mitigation in plant maintenance
   • Categorising technical, environmental and safety maintenance risks
   • Structuring a formal maintenance risk management framework
   • Integrating risk assessment tools into routine maintenance procedures
   • Ensuring regulatory compliance, statutory inspections and workplace safety
9. Module 9

   Continuous improvement and advanced maintenance practices

   • Applying Lean maintenance principles to eliminate process waste
   • Workplace organisation and standardisation using the 5S Methodology
   • Total Productive Maintenance (TPM) pillars and autonomous operator maintenance
   • Integrating Industrial Internet of Things (IIoT) sensors and predictive analytics
   • Benchmarking maintenance performance against global industry leaders