This workshop provides a structured, practical approach to building an effective maintenance program based on Reliability-Centered Maintenance (RCM). Participants learn how to shift from reactive or overly conservative time-based maintenance to a risk-informed, evidence-based program that improves plant availability and safety while reducing unnecessary work. The course connects key reliability concepts (reliability, maintainability, availability, failure rate, P–F interval, bathtub curve) with hands-on RCM/FMEA methodology—functions, functional failures, failure modes, effects, safeguards, and actionable maintenance plans. Realistic plant examples (e.g., cooling water/condensate pump systems and a hydrocracker reactor case) are used to demonstrate how to build traceable, auditable maintenance logic suitable for CMMS implementation.

• Maintenance and Reliability Engineers (mechanical/electrical/instrumentation)
• Operations engineers/supervisors responsible for equipment uptime and safe operation
• Asset integrity / inspection engineers and rotating equipment specialists
• Project and commissioning engineers transitioning equipment into reliable operation
• Maintenance planners, CMMS key users, and technical managers

Day 1:

8:00 AM – 9:00 AM Register

9:00 AM – 12:00 PM
Module 1: Why RCM – Maintenance Evolution and Common Pitfalls
• Evolution of maintenance expectations and techniques
• Common maintenance problems
• Why OEM manuals can lead to over-maintenance
• Business drivers

Module 2: Reliability, Maintainability, and Availability – Practical Engineering Metrics
• Definitions and relationships: R(t) + F(t) = 1
• Availability as a combined measure of reliability and maintainability
• System reliability and “weakest link” concept
• Failure behavior concepts

12:00 PM – 13:00 PM Lunch Break

13:00 PM – 17:00 PM
Module 3: P–F Interval and Condition Monitoring Logic
• Functional failure vs potential failure
• Selecting the right health indicator
• Choosing maintenance tasks

Module 4: RCM Framework – The 7 Basic RCM Questions and Workflow
• The 7 basic RCM questions: functions, failures, causes, effects, consequences, proactive tasks, and default actions
• RCM process flow

Day 2:
8:00 AM – 9:00 AM Register

9:00 AM – 12:00 PM
Module 5: Practical FMEA Methodology (Workshop Core)
• How to write good failure modes
• Failure effects writing
• Safeguards
• Action plans
• Required inputs
• Templates and worksheets for FMEA

Module 6: Case Studies and Syndicate Exercises
• Cooling water pump example
• Condensate pump example
• Hydrocracker reactor proactive plan
• How to convert workshop outputs into an implementable proactive maintenance program

12:00 PM – 13:00 PM Lunch Break

13:00 PM – 17:00 PM

Module 7: Implementation – Cost, CMMS, Spares, and Performance Management
• Maintenance vs opportunity costs
• Integrated maintenance management concepts and ‘high-technology maintenance’ design basis
• CMMS/engineering computer systems
• Spare parts strategy
• Continuous improvement and standardization opportunities
• Maintenance KPIs: Emergency Percentage Index (EMP), Maintenance Overtime Percentage (MOP), Equipment Availability (EQA), % Equipment Covered by RCM Plan (PCE)