Course Overview
This comprehensive professional development program is designed for All Professionals who are employed in the Maintenance department and want to learn advanced techniques on maintenance management, Maintenance operations teams, Maintenance supervisors, Maintenance engineers, Maintenance team leaders and managers, and Operations team leaders and managers responsible for implementing advanced maintenance management across automotive, electronics, manufacturing, and multi-organizational contexts. The program addresses proven practices in structured PM and TPM intervention, advanced maintenance cost reduction and productivity improvement, and balanced-scorecard-aligned KPI management where TBM Consulting Group case showing structured preventive-maintenance and reliability intervention focusing on critical conveyors and partnering with specialist contractor and clearing backlog of PM tasks and introducing oil-sampling on key gearboxes reducing equipment downtime and improving plant’s ability to deliver quality parts on time, NIST study reporting firm-level cases where moving from reactive to predictive and reliability-centered maintenance reduces maintenance costs by 15–98 percent and cuts breakdowns and downtime and increases productivity and output with overall returns on investment generally favorable, and Brazilian balanced-scorecard TPM study showing how maintenance performance indicators can be aligned with organizational strategy across financial and client and internal processes and learning-and-growth perspectives and linked in cause-and-effect strategic map.
The curriculum integrates The Manager’s Role in the Workplace, Strategic Planning for Goal Achievement, Maintenance of World-Class Concept and Level, Visionary Leadership Traits, Strategic Implementation and Receiving the Value out of Strategy, and Controlling to Improve Results to provide comprehensive coverage of advanced maintenance management principles, strategic planning frameworks, and KPI and balanced-scorecard domains for achieving world-class maintenance management excellence.
Why This Course Is Required?
Structured PM and TPM intervention and downtime reduction represent critical competencies where TBM Consulting Group case showing US automotive components manufacturer whose conveyor systems were causing frequent downtime and jeopardizing delivery performance with targeted maintenance intervention identifying and prioritizing most critical conveyors and engaging local specialist contractor and catching up on overdue preventive-maintenance work and implementing oil-sampling program on critical gearboxes reducing unplanned stoppages and improving on-time delivery of parts illustrating tangible benefits of structured PM and TPM practices and better work management. Advanced maintenance cost reduction and productivity improvement demand specialized knowledge where NIST study reporting firm-level cases where moving from reactive to predictive and reliability-centered maintenance reduces maintenance costs by 15–98 percent and cuts breakdowns and downtime and increases productivity and output with census data estimating $50 billion spent on maintenance and repair in 2016 and maintenance estimated to be between 15 percent and 70 percent of cost of goods produced. Balanced-scorecard-aligned KPI management and strategic maintenance alignment require professionals with advanced maintenance expertise where Brazilian study showing maintenance performance indicators can be aligned with organizational strategy across four perspectives and linked in cause-and-effect strategic map with research confirming that when maintenance KPIs are structured within balanced-scorecard framework maintenance departments can better support business goals and avoid one-dimensional cost cutting and drive continuous improvement.
Advanced maintenance management professionals must master manager’s role fundamentals including what is management and manager versus supervisor and five skills of management process and how managerial levels differ and manager tips and management principles and managerial job roles and managers goals and how managerial performance is judged, understand comprehensive strategic planning frameworks including what is planning and who is responsible for planning and mission and vision and value statements and strategic plan and goals and objectives and policies and procedures and standards and forms of planning including strategic and tactical and operational and contingency and planning tools including analytical tools and organizational tools, and apply proper controlling-to-improve-results methods including what is control and control process and control pyramid and key performance indicators and definition and purpose and guiding principles and maintenance and reliability KPIs and balanced scorecards to ensure organizations achieve superior structured PM and TPM intervention and downtime reduction, enhanced advanced maintenance cost reduction and productivity improvement, improved balanced-scorecard-aligned KPI management and strategic maintenance alignment, and competitive advantage through strategy formulation, implementation, and continuous performance measurement protocols.
Research demonstrates training is crucial for success, with TBM case showing maintenance leaders who can interpret downtime data and prioritize critical assets and coordinate with external service providers and enforce disciplined preventive-maintenance routines becoming central to improving throughput and quality and delivery performance with by covering the manager’s role and strategic and operational planning and world-class maintenance concepts course equipping with skills to play that kind of leadership role, while NIST analysis indicating engineers and managers who champion advanced maintenance techniques including condition-based maintenance and reliability-centered maintenance and TPM can justify investments by quantifying reductions in failures and downtime and defects and lost sales as well as gains in capacity and product quality with course’s focus on strategy formulation and implementation and performance measurement helping build robust business cases and manage strategic change required to move from reactive to proactive and predictive maintenance, and balanced-scorecard TPM study showing maintenance professionals who can design and use a scorecard selecting critical few KPIs in financial and customer and process and learning dimensions and understanding their cause-and-effect relationships being better able to align daily maintenance decisions with long-term strategic objectives with course’s module on controlling to improve results mirroring this approach.
Course Objectives
- Leveraging the value of strategic planning by applying mission, vision, and SWOT/PESTLE analysis tools to formulate and communicate a maintenance strategy with clear goals, objectives, and aligned policies, and by distinguishing between strategic, tactical, operational, and contingency planning levels.
- Creating and implementing robust maintenance strategy by aligning culture, structure, and people with strategic intent, translating strategic analysis into operational plans and work-management workflows, and managing the change process required to move from reactive to proactive and predictive maintenance.
- Analyzing options and making choices in setting goals and objectives by identifying the most critical assets and failure risks, evaluating advanced maintenance techniques (PM, TPM, CBM, RCM), quantifying potential cost and productivity impacts, and building a defensible business case for investment.
- Monitoring and measuring performance by designing and using a balanced scorecard that structures maintenance KPIs (availability, cost, backlog, training) across financial, client, internal-process, and learning-and-growth perspectives, linking them through cause-and-effect chains so daily maintenance decisions stay aligned with long-term organisational strategy.
Master advanced maintenance management excellence and drive structured PM optimization and strategic performance success. Enroll today to become a Certified Advanced Maintenance Management Professional!
Training Methodology
This interactive Advanced Maintenance Management Certification Training program comprises the following training methods:
The training framework includes:
- Lectures
- Seminars and Presentations
- Group Discussions
- Assignments
- Case Studies and Functional Exercises
- Workshops developing strategic planning and KPI design skills
- Hands-on exercises practicing balanced scorecard development and CMMS utilization
- Practical demonstrations with maintenance strategy formulation scenarios and TPM implementation techniques
This immersive approach fosters practical skill development and real-world application of advanced maintenance management principles through comprehensive coverage of maintenance management principles, strategic planning frameworks, and KPI and balanced-scorecard domains with emphasis on measurable downtime reduction and cost optimization and productivity improvement.
This program follows the Do-Review-Learn-Apply model, creating a structured learning journey that transforms traditional maintenance approaches into advanced maintenance management excellence.
Who Should Attend?
This Advanced Maintenance Management Training Course is designed for:
- All professionals who are employed in the Maintenance department and want to learn advanced techniques on maintenance management
- Maintenance operations teams
- Maintenance supervisors
- Maintenance engineers
- Maintenance team leaders and managers
- Operations team leaders and managers
- Reliability engineers
- Plant and production managers
Organizational Benefits
Organizations implementing advanced maintenance management training will benefit through:
- Significantly enhanced structured PM and TPM intervention and downtime reduction through comprehensive training delivering measurable returns where TBM Consulting Group case showing US automotive components manufacturer implementing targeted maintenance intervention identifying and prioritizing most critical conveyors and engaging local specialist contractor and catching up on overdue PMs and implementing oil-sampling program on critical press and conveyor gearboxes reducing unplanned stoppages and improving on-time delivery of parts exactly what training teaches
- Better advanced maintenance cost reduction and productivity improvement through NIST study reporting firm-level cases where moving from reactive to predictive and reliability-centered maintenance reduces maintenance costs by 15–98 percent and cuts breakdowns and downtime and increases productivity and output with investment in advanced maintenance techniques having return on investment of 10:1 and case study showing plant operating at only 57 percent of true capacity improving to 94 percent capacity after adopting advanced maintenance techniques resulting in $17.22 million increase in revenue in first two years as organizational benefits highlighted in training
- Improved balanced-scorecard-aligned KPI management and strategic maintenance alignment through Brazilian study showing maintenance performance indicators structured within balanced-scorecard framework allowing maintenance departments to better support business goals and avoid one-dimensional cost cutting and drive continuous improvement with maintenance indicators such as equipment availability and maintenance cost and backlog and training structured under financial and client and internal-process and learning-and-growth perspectives validating course content
- Strengthened competitive advantage through ISO factor where many companies implementing ISO as maintenance system now required under ISO 9002 and productivity factor where companies turning toward CMMS and TPM to gain advantage over competitors and cost factor where successful maintenance management program results in savings in maintenance time and costs and increases productivity and comprehensive understanding of advanced maintenance management principles enabling superior maintenance excellence
Studies show that organizations implementing comprehensive advanced maintenance management training achieve significantly enhanced delivery outcomes as research confirms NIST study showing adoption of advanced maintenance practices reducing maintenance costs ranging from 15 percent to 98 percent at firm level with reduction in defects and rework ranging up to 90 percent and reduction in breakdowns ranging up to 45 percent and increase in output and production ranging up to 58 percent and reduction in downtime ranging up to 50 percent reinforcing course’s emphasis on strategic and operational maintenance management, better organizational outcomes through TPM evidence demonstrating balanced-scorecard implementation showing training and standardization improving process indicators which in turn improve customer satisfaction and financial results demonstrating how maintenance teams can use scorecard to guide strategic initiatives and monitor progress, and improved competitive positioning as advanced maintenance approach enables better profitability while organizations benefit from reviewing and assessing critical operational requirements for successful planning and control of maintenance work and using precise KPIs for measurement and evaluation of maintenance department.
Empower your organization with advanced maintenance management expertise. Enroll your team today and see the transformation in PM optimization and strategic performance!
Personal Benefits
Professionals implementing advanced maintenance management training will benefit through:
- Deeper understanding of downtime-data-interpretation mastery and maintenance-leadership centrality through TBM Consulting Group case showing maintenance leaders who can interpret downtime data and prioritize critical assets and coordinate with external service providers and enforce disciplined preventive-maintenance routines becoming central to improving throughput and quality and delivery performance with by covering manager’s role and strategic and operational planning and world-class maintenance concepts course equipping with skills to play that kind of leadership role in own maintenance department
- Enhanced advanced-maintenance-techniques mastery and investment-justification capability through NIST analysis indicating engineers and managers who champion advanced maintenance techniques including condition-based maintenance and reliability-centered maintenance and TPM can justify investments by quantifying reductions in failures and downtime and defects and lost sales as well as gains in capacity and product quality with course’s focus on strategy formulation and implementation and performance measurement helping build robust business cases and manage strategic change required to move from reactive to proactive and predictive maintenance
- Stronger balanced-scorecard-KPI mastery and strategic-alignment capability through balanced-scorecard TPM study showing maintenance professionals who can design and use a scorecard selecting critical few KPIs in financial and customer and process and learning dimensions and understanding their cause-and-effect relationships being better able to align daily maintenance decisions with long-term strategic objectives with course’s module on controlling to improve results mirroring this approach giving practical tools to monitor performance and judge managerial effectiveness and sustain continuous improvement
- Advanced expertise in maintenance management principles, strategic planning frameworks, and KPI and balanced-scorecard domains
- Enhanced career prospects and marketability in maintenance management, reliability engineering, plant operations, and strategic maintenance leadership sectors with professionals gaining skills in strategic planning, TPM implementation, and CMMS utilization
- Ability to gain new and modern concepts and techniques and strategies in maintenance management
- Skills to develop leadership and managerial capabilities to improve performance of maintenance units
- Knowledge to gain concepts and techniques necessary for effectively planning and scheduling and controlling maintenance activities
- Capability to manage and administer routine and corrective as well as large-scale preventive maintenance activities
Course Outline
Module 1 – The Manager’s Role in the Workplace
- What is Management?
- Manager or Supervisor – What’s the difference?
- 5 skills of the management process
- How are managerial levels different?
- Manager Tips
- Management Principles
- Managerial job roles
- Managers Goals
- How is Managerial Performance judged?
- Linking maintenance results to managerial performance
- Developing maintenance-focused leadership behaviours
Module 2 – Strategic Planning for Goal Achievement
- What is Planning all about?
- Who is responsible for planning? – Planning levels
- Mission, Vision, and Value Statements
- Strategic Plan
- Goals, Objectives, Policies, Procedures, and Standards
- Forms of Planning
- Strategic Planning
- Tactical Planning
- Operational Planning
- Contingency Planning
- Planning tools
- Analytical tools
- Needs Assessment
- SWOT Analysis
- PEST Analysis
- PESTLE Analysis
- Organizational tools
- Project Plan
- PERT Chart
- Gantt Chart
- Analytical tools
- The building, adapting and communicating strategy
- Translating strategy into maintenance objectives and plans
- Prioritising maintenance initiatives in the strategic plan
Module 3 – Maintenance of World-Class Concept and Level
- Maintenance maturity and evolution
- Maintenance Strategy; vision, mission, goals and objectives
- Maintenance organization “roles & responsibilities”
- RACI Model for maintenance
- Work management and Workflow
- Defining world-class maintenance performance levels
- Assessing current maintenance maturity and gaps
Module 4 – Visionary Leadership Traits
- Leader Vs. Manager
- Basic skills
- Levels of leadership
- Situational Leadership
- SWOT and PESTLE Analysis
- Strategic issues
- Culture change
- Empowering leadership
- Leading the shift from reactive to proactive maintenance
- Engaging teams in TPM and continuous improvement
Module 5 – Strategic Implementation and Receiving the Value out of Strategy
- Alignment of Strategy, Culture, Structure and People
- Effective Execution – converting and translating strategic analysis and planning into action
- Aligning and Linking Strategy with Operational Objectives
- Implementation – getting practical things done
- Creating Tomorrow’s Organization out of Today’s Organization
- Strategic Planning at a Personal Level
- Overview: The Complete Strategy Process
- Selecting key maintenance projects to realise strategy
- Tracking benefits from maintenance initiatives
Module 6 – Controlling to Improve Results
- What is Control?
- The control process
- The control pyramid
- Key Performance Indicators (KPI)
- Definition and Purpose
- Guiding Principles
- Maintenance & Reliability KPI
- Balanced Score Cards
- Building a maintenance KPI dashboard
- Using KPIs and BSC for continuous improvement
Real World Examples
TBM Consulting Group – US automotive components manufacturer
Implementation: TBM Consulting Group reports on US automotive parts supplier where daily random equipment breakdowns and conveyor issues caused work stoppages, missed shipment risks, and extensive overtime, with maintenance almost entirely reactionary and no permanent maintenance manager. TBM conducted in-depth assessment and proposed multi-pronged TPM program including redeploying maintenance workers across shifts and adding contractors, creating scheduling system for maintenance and tooling work orders with visual planning and status boards, daily cross-functional maintenance status reviews, analyzing existing downtime data to reveal conveyors as primary cause of downtime, partnering with local service provider to assess all 120 conveyors and repair most critical issues first, catching up on overdue PMs throughout plant, and initiating oil-sampling program on press and conveyor gearboxes, especially those difficult to access.
Results: Company reduced unplanned stoppages and improved ability to deliver quality parts on time while reducing firefighting maintenance behavior, ultimately hiring full-time maintenance manager and extending improved maintenance program to another plant, demonstrating that disciplined PM, TPM practices, and systematic work management directly reduce equipment downtime and support profitable fulfillment of customer orders.
NIST – Electronics manufacturer and other industrial firms
Implementation: NIST report on advanced maintenance compiles cases from electronics and discrete-manufacturing firms where adoption of predictive and reliability-centered maintenance increased effective capacity and reduced quality-related losses and lowered maintenance and operating costs. In one highlighted case, plant previously operating at only 57 percent of true capacity formed team to address reliability problems, invested about USD 1.35 million in consulting and training and changed maintenance and changeover practices, and implemented advanced maintenance techniques.
Results: Maintenance costs increased 10 percent in first year but then decreased in subsequent years, capacity increased to 94 percent, and quality losses fell from 9 percent to 4 percent, generating about USD 17.22 million additional revenue in two years, with literature surveyed by NIST showing predictive maintenance can reduce maintenance costs 15–98 percent and yield high returns on investment, confirming that strategic maintenance initiatives directly impact profitability and competitiveness.
Brazilian TPM implementation – Industrial maintenance organization
Implementation: Brazilian study applied Balanced Scorecard to Planned Maintenance pillar of TPM in industrial maintenance organization, structuring maintenance indicators such as equipment availability and maintenance cost and corrective-maintenance backlog and training under financial and client and internal-process and learning-and-growth perspectives and building strategic map linking indicators through cause-and-effect chains for example, training and standardization in learning-and-growth improving internal processes, which raises client satisfaction, which then improves financial metrics.
Results: Implementation showed maintenance department could use scorecard to select “critical few” indicators, monitor progress of TPM initiatives, avoid pure cost-cut focus, and support strategic objectives, confirming value of embedding maintenance KPIs in balanced-scorecard framework, mirroring this course’s module on controlling to improve results using KPIs and Balanced Score Cards to judge managerial performance and sustain continuous improvement.
Be inspired by leading advanced maintenance management achievements. Register now to build the skills your organization needs for strategic, high-performance maintenance excellence!
