Introduction
Efficient maintenance is a cornerstone of asset management, equipment reliability, and operational continuity. Poor maintenance planning leads to equipment breakdowns, production delays, increased costs, and safety risks. This training program equips professionals with industry best practices, tools, and techniques for proactive maintenance planning, precise scheduling, and effective control.
Participants will learn how to structure maintenance systems, forecast resource needs, plan preventive tasks, manage backlogs, and improve plant uptime. The course integrates practical sessions, case studies, and global standards like CMMS, RCM, and TPM to optimize the maintenance lifecycle in manufacturing, utilities, oil & gas, construction, and related industries.
Participants who successfully complete the course will receive a Certificate of Participation.
Course Objectives
By the end of the training, participants will be able to:
- Understand the principles of maintenance management, planning, and control.
- Develop maintenance plans aligned with equipment criticality and risk.
- Use preventive, predictive, and corrective maintenance strategies effectively.
- Apply best practices in job planning, materials forecasting, and crew scheduling.
- Manage maintenance backlogs and ensure schedule compliance.
- Analyze maintenance performance and use KPIs for decision-making.
- Optimize asset availability and extend equipment life cycles.
- Utilize Computerized Maintenance Management Systems (CMMS) and tools.
- Link maintenance practices with safety, quality, and operational goals.
Who Should Attend:
This course is designed for:
- Maintenance Planners and Engineers
- Plant Engineers and Supervisors
- Operations and Production Managers
- Reliability Engineers
- Maintenance Coordinators and Team Leaders
- Technical Officers and Foremen
- Facility and Asset Managers
- CMMS Users and Maintenance Analysts
- Safety and Quality Assurance Personnel involved in maintenance activities
Course Duration
5 Days
Course Outline
Module 1: Fundamentals of Maintenance Management
- Introduction to Maintenance Management and Asset Care
- Types of Maintenance:
- Reactive (Breakdown)
- Preventive (Time-Based)
- Predictive (Condition-Based)
- Proactive and Reliability-Centered Maintenance (RCM)
- Objectives of Planning, Scheduling, and Control
- Role of Maintenance in Safety, Reliability, and Cost Control
- Organizational Structure and Communication in Maintenance
- Overview of Maintenance Life Cycle
- Roles and Responsibilities of Planners, Supervisors, and Technicians
- Introduction to Maintenance Work Orders
Module 2: Maintenance Planning Processes
- Maintenance Planning Workflow
- Identifying and Classifying Maintenance Work
- Defining Scope of Work and Work Breakdown
- Maintenance Task Lists and Job Plans
- BOMs (Bills of Materials) and Spare Parts Identification
- Estimating Labor, Tools, and Material Requirements
- Planning for Safety and Permits
- Criticality and Risk-Based Prioritization of Equipment
- Maintenance Planning Templates and Checklists
Case Exercise: Creating a Maintenance Plan for a Pump System
Module 3: Maintenance Scheduling Techniques
- Scheduling Principles and Objectives
- Creating Weekly, Monthly, and Long-Term Schedules
- Managing the Maintenance Calendar
- Matching Resources with Job Plans (Manpower Loading)
- Leveling Workloads and Avoiding Over-Scheduling
- Coordination Between Maintenance and Production
- Shutdown and Turnaround Planning
- Emergency and Breakdown Job Handling
- Use of Gantt Charts, CPM, and Bar Charts
Group Exercise: Scheduling Using Templates or CMMS Demo
Module 4: Maintenance Control and Performance Monitoring
- Execution of Maintenance Jobs
- Supervision, Communication, and Feedback
- Job Close-Out Procedures
- Backlog Management and Prioritization
- Controlling Work Execution and Cost
- Maintenance KPIs and Performance Metrics:
- PM Compliance
- MTBF, MTTR
- Schedule Compliance
- Wrench Time
- Reporting and Documentation
- Root Cause Analysis of Failures
- Auditing and Continuous Improvement
Case Study: Analysis of Poor Scheduling Outcomes
Module 5: Systems, Technology, and Strategic Maintenance
- Computerized Maintenance Management Systems (CMMS):
- Features and Benefits
- Work Order Processing
- Data Collection and Reporting
- Maintenance Planning with ERP Systems
- Digital Tools: Sensors, IoT, Mobile Apps
- Integration of TPM (Total Productive Maintenance)
- Reliability-Centered Maintenance (RCM) Concepts
- Maintenance Budgeting and Cost Optimization
- Contractor Management in Maintenance Work
- Strategic Planning for Maintenance Excellence
Final Workshop: Developing a Full Maintenance Planning & Scheduling Framework
General Notes
- The instructor led trainings are delivered using a blended learning approach and comprises of presentations, guided sessions of practical exercise, web-based tutorials and group work. Our facilitators are seasoned industry experts with years of experience, working as professional and trainers in these fields.
- The participants should be reasonably proficient in English as all facilitation and course materials will be offered in English.
- Upon successful completion of this training, participants will be issued with a certificate.
- The training will be held at Kincaid Training Centre. The course fee covers the course tuition, training materials, two break refreshments and lunch.
- All participants will additionally cater for their, travel expenses, visa application, insurance, and other personal expenses.
- Accommodation and airport pickup are arranged upon request. For reservations contact the Training coordinator at Email: training@kincaiddevelopmentcenter.org or Tel: +254 724592901
- This training can also be customized to suit the needs of your institution upon request. You can have it delivered in our Kincaid Training Centre or at a convenient location.
For further inquiries, please contact us on Tel: +254 724592901 or send mail to training@kincaiddevelopmentcenter.org.
Payments are due upon registration. Payment should be sent to our Bank account before commencement of training and proof of payment sent to training@kincaiddevelopmentcenter.org.