Course Overview
What is the objective of maintenance and reliability? Being a plant engineer means facing a real challenge in how to manage things going around you. Gaining knowledge of best practices in maintenance and reliability and to learn how to implement these practices is the key to a successful management strategy and better aligning to company goals and objectives.
This Zoe training course provides a no-nonsense, practical and real-world systematic approach to best-managed maintenance. Participants’ specific needs and concerns are also addressed during the training so that they can go back to their workplace and immediately apply what they’ve learned. This Maintenance and Reliability Best Practices course can also be adopted as part of a company’s regular qualified maintenance & reliability program.
Why This Course Is Required?
Maintenance and reliability best practices are essential for modern industry to ensure high asset performance, minimize downtime, and support safe, profitable operations where recent research demonstrates that organizations transitioning from reactive and basic preventive approaches to advanced, data-driven reliability strategies consistently achieve lower operating costs, improved safety, and higher availability of critical equipment. The complexity of modern industrial operations requires specialized knowledge in root cause failure analysis, structured work management, and asset health monitoring to align with international standards like ISO 55000 while driving continuous improvement and success across manufacturing, utilities, and process sectors.
The essential need for comprehensive training in maintenance and reliability best practices is underscored by the critical role of systematic reliability initiatives in preventing equipment failures and optimizing asset performance where proper understanding of Failure Modes and Effects Analysis (FMEA), predictive maintenance, and condition-based monitoring is crucial for achieving world-class maintenance performance. Maintenance professionals must master the principles of Reliability Centered Maintenance (RCM), understand asset criticality analysis and data-driven decision making, and apply proper performance management techniques to foster a culture of ownership between operations and maintenance while delivering sustained cost, safety, and quality gains.
Research demonstrates that maintenance and reliability best practices are essential for modern industry to ensure high asset performance, minimize downtime, and support safe, profitable operations, with recent peer-reviewed research showing that organizations transitioning from reactive and basic preventive approaches to advanced, data-driven reliability strategies consistently achieve lower operating costs, improved safety, and higher availability of critical equipment through embracing root cause failure analysis, structured work management, and asset health monitoring aligned with international standards.
Course Objectives
Participants attending the Maintenance and Reliability Best Practices training programme will:
- Interpret 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
- Learn and practise the activities used to gauge and assess the current capabilities of the equipment & processes in terms of their reliability, availability, maintainability & criticality
- Practise and exercise on activities which are used to select & apply the utmost appropriate maintenance practices, so that the equipment & processes remain to provide and deliver their intended capabilities in the safest, securest and most cost-effective manner
- Learn and apply the processes for confirming that the maintenance & reliability staff is the most qualified and best assigned to achieve the maintenance & reliability organization goals
- Learn the skills used to get the maintenance & reliability work done. This involves scheduling and planning of activities, quality assurance of maintenance activities, stores and inventory management
- Acquire the knowledge of how to select Maintenance & Reliability benchmarks
- Advanced competency in asset criticality analysis and reliability engineering methodologies
- Expertise in condition-based maintenance technologies and predictive maintenance strategies
- Enhanced understanding of Key Performance Indicators (KPIs) for maintenance performance management
- Skills in Total Productive Maintenance (TPM) implementation and Overall Equipment Effectiveness (OEE) optimization
- Proficiency in Root Cause Analysis (RCA) and failure prevention techniques
Master maintenance and reliability excellence and drive operational performance. Enroll today to become an expert in Maintenance and Reliability Best Practices!
Training Methodology
The programme will be interactive and practical. There will be activities in groups as well as individual exercises and everyone will get an opportunity to discuss their experience and issues with maintenance & reliability management problems. Each day will end with time to create an action plan for delegates’ continuing development.
The training framework includes:
- Expert-led lectures delivered by experienced maintenance and reliability professionals
- Seminars and presentations covering real-world applications and industry best practices
- Group discussions that encourage experience sharing and issue resolution
- Assignments that reinforce key maintenance and reliability concepts
- Case studies and functional exercises based on actual industrial scenarios
- Individual action planning sessions for continuing development
This collaborative approach fosters practical skill development and real-world application of maintenance and reliability principles through comprehensive coverage of strategic frameworks, work management processes, and performance optimization techniques.
Zoe Talent Solutions follows the ‘Do-Review-Learn-Apply’ model, creating a structured learning journey that transforms maintenance and reliability knowledge into operational excellence through systematic practice and implementation.
Who Should Attend?
This seminar is designed for:
- Plant engineers working in any maintenance & reliability field who need to sharpen their maintenance management skills and gain more knowledge to increase efficiencies and uptime
- Operation and quality engineers and technicians who need to understand maintenance work perspectives
- General maintenance personnel working with equipment and systems at industrial plants, commercial buildings, or private facilities
- Technicians in cross-training programs seeking comprehensive maintenance knowledge
- Maintenance supervisors and managers responsible for reliability programs
- Reliability engineers and asset management professionals
- CMMS administrators and maintenance planners
- Operations managers with maintenance oversight responsibilities
- Quality assurance personnel involved in maintenance processes
- Safety managers with equipment maintenance responsibilities
- Facility managers responsible for building and infrastructure maintenance
- Consultants and contractors providing maintenance and reliability services
Organisational Benefits
Companies who nominate their employees to participate in this Maintenance and Reliability Best Practices Course can benefit in the following ways:
- Learn how to design a maintenance program & strategy using RCM
- Understand several types of CBM and the technologies used
- Be able to design balanced scorecards and how to align performance with organizational goals
- Significant reduction in downtime and costs through systematic reliability initiatives that reduce unexpected failures by up to 55%
- Decreased maintenance costs by as much as 50% and spare parts inventory reduction by 30%
- Improved asset and process performance through criticality ranking and condition-based maintenance
- Enhanced cultural transformation fostering ownership and teamwork between operations and maintenance
- Better resource allocation and work execution through structured planning and scheduling
- Strengthened competitive advantage through global benchmarking and continuous improvement
Studies show that organizations implementing comprehensive maintenance and reliability best practices training achieve reduced downtime and costs as systematic reliability initiatives such as FMEA, predictive maintenance, and scheduled planning reduce unexpected failures by up to 55%, maintenance costs by as much as 50%, and spare parts inventory by 30%, while improving asset and process performance through organizations applying criticality ranking and condition-based maintenance that realize greater asset utilization, and fostering cultural and continuous improvement as advanced reliability programs empower companies to benchmark globally and deliver further cost, safety, and quality gains.
Empower your organization with maintenance and reliability excellence. Enroll your team today and see the transformation in asset performance and operational efficiency!
Personal Benefits
Individuals who participate in this Maintenance and Reliability Best Practices Course can gain from it in the following ways:
- Learn approaches of maintenance and other maintenance practices
- Understand the difference between planning & scheduling
- Interpret the objective of maintenance storerooms
- Be familiar with TPM pillars
- Advanced expertise in maintenance and reliability engineering and strategic planning
- Enhanced career prospects and marketability in manufacturing and process industries
- Improved ability to lead maintenance transformation initiatives and reliability programs
- Greater competency in asset management and condition monitoring technologies
- Increased capability to optimize maintenance costs and improve operational efficiency
- Enhanced understanding of international standards and benchmarking practices
Course Outline
Module 1: Introduction to M & R, Culture & Leadership
- Maintenance & Reliability Best Practices
- Leadership & organizational culture
- Strategic framework: Vision, Mission & Goals
- Change Management
- Reliability Culture
- Measure of performance
- Cultural transformation fostering ownership between operations and maintenance
- Management engagement and leadership commitment to reliability excellence
- Strategic alignment between maintenance goals and business objectives
- Change management principles for reliability program implementation
Module 2: Understanding Maintenance
- What is maintenance?
- A new paradigm of maintenance – Capacity assurance
- Maintenance Approaches
- Other maintenance practices
- Maintenance Management System (CMMS)
- Maintenance quality
- Maintenance assessment and improvement
- Evolution from reactive to preventive to predictive maintenance strategies
- Capacity assurance versus traditional equipment availability focus
- Computerized Maintenance Management Systems (CMMS) for automation and data management
- Maintenance quality assurance and continuous improvement methodologies
Module 3: Work Management: Planning & Scheduling
- Workflow & roles
- Work classification & prioritization
- Planning process
- Scheduling process
- Turnarounds & shutdowns
- Measure of performance
- Work order management and priority classification systems
- Resource optimization and maintenance scheduling best practices
- Planned versus unplanned work ratios and performance metrics
- Shutdown and turnaround planning methodologies
Module 4: Materials, Parts & Inventory Management
- Types of inventory
- Physical layout and storage equipment
- Optimizing tools & techniques
- Measure of performance
- Spare parts inventory optimization reducing inventory by up to 30%
- Strategic inventory management and vendor collaboration
- Materials planning and just-in-time inventory approaches
- Obsolete inventory management and lifecycle planning
Module 5: Measuring & Designing for Reliability & Maintainability
- Defining & Measuring reliability & other terms
- Designing & Building for Maintenance & Reliability
- Reliability engineering principles and failure mode analysis
- Design for maintainability and accessibility considerations
- Life cycle cost analysis and reliability-centered design
- Maintainability metrics and design optimization techniques
Module 6: Operator Driven Reliability
- The role of operations
- Total Productive Maintenance (TPM)
- Workplace management: 5S
- Overall equipment effectiveness (OEE)
- Measure of performance
- TPM pillar implementation and autonomous maintenance development
- Operator-led maintenance training and skill development
- 5S workplace organization and visual management systems
- OEE calculation and improvement strategies for production optimization
Module 7: Maintenance Optimization
- Understanding failures & maintenance strategies
- Maintenance Strategy – RCM
- Maintenance Strategy – CBM
- Other maintenance strategies
- Reliability Centered Maintenance (RCM) implementation and decision logic
- Condition-Based Maintenance (CBM) technologies including vibration analysis and thermal imaging
- Predictive maintenance programs reducing breakdowns by up to 70%
- Failure Mode and Effects Analysis (FMEA) for systematic reliability improvement
Module 8: Managing Performance & Workforce Management
- Identifying performance measures
- Data collection & data quality
- Benchmarking & Benchmarks
- Employee life cycle
- Understanding the generation gap
- Communication skills
- People development
- Key Performance Indicators (KPIs) including MTBF, MTTR, and PM compliance
- Data-driven decision making and analytics for maintenance optimization
- Benchmarking against industry best practices and world-class performance
- Workforce development and skills training for maintenance excellence
- Root Cause Analysis (RCA) methodologies for failure prevention and continuous improvement
- Communication protocols and cross-functional collaboration strategies
Real World Examples
The impact of Maintenance and Reliability Best Practices training is evident in leading implementations:
- Best-in-Class Manufacturing Transformation (Global Industries)
Implementation: According to systematic review by Benhanifia et al. (2025), best-in-class organizations succeeded by moving from preventive maintenance-centric to predictive maintenance-centric operations, supported by robust asset registries, failure mode logic, and management engagement through comprehensive reliability transformation programs.
Results: The implementation achieved documented reductions in maintenance costs and equipment failures while increasing machine uptime, enhanced operational performance through data-driven reliability strategies, and improved safety through systematic asset health monitoring, demonstrating how comprehensive maintenance and reliability training enables exceptional operational transformation and performance optimization. - Asset Criticality and Reliability Engineering Excellence (Process Industries)
Implementation: Leading process industries have implemented comprehensive reliability engineering programs utilizing asset criticality analysis and data-driven decision making, using RCM (Reliability Centered Maintenance) and advanced condition-monitoring technologies to optimize resource allocation and maximize asset availability.
Results: The implementations have achieved enhanced asset performance through systematic criticality ranking and condition-based maintenance, improved resource allocation through data-driven reliability strategies, and strengthened operational efficiency through integrated preventive and predictive maintenance approaches, showcasing how systematic reliability training enables superior asset management and operational excellence. - Integrated Maintenance Excellence Programs (Manufacturing Sector)
Implementation: Manufacturing organizations have implemented comprehensive maintenance excellence programs that blend preventive measures with vibration analysis, oil condition monitoring, and failure analysis frameworks, utilizing actionable KPIs including Mean Time Between Failures, PM compliance, and percent of planned work to focus improvements.
Results: The programs have achieved top-tier performance while avoiding over-maintenance through balanced preventive and predictive approaches, enhanced operational reliability through systematic condition monitoring and failure analysis, and sustained performance gains through continuous improvement and benchmarking practices, demonstrating how comprehensive maintenance training enables superior manufacturing performance and reliability excellence.
Be inspired by industry-leading maintenance and reliability achievements. Register now to build the skills your organization needs for operational excellence!
