MAINTENANCE & RELIABILITY GAP ANALYSIS & OPTIMIZATION
Closing Performance Gaps and Building High-Reliability Maintenance Systems
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 18 – 22 May 2026 | Singapore | USD 3495 per delegate |
Course Introduction
Modern industrial operations depend heavily on reliable assets and well-structured maintenance systems. However, many organizations face persistent gaps between current practices and world-class standards—resulting in unplanned downtime, excess costs, and safety risks.
This comprehensive 5-day course empowers maintenance, engineering, and operations professionals to systematically assess their existing programs and close performance gaps. Participants will learn proven frameworks such as Reliability-Centered Maintenance (RCM), Total Productive Maintenance (TPM), and ISO 55000. Through benchmarking, diagnostics, and interactive workshops, the course equips teams to optimize asset performance and build a culture of continuous improvement.
Course Objectives
By the end of this course, participants will be able to:
• Conduct a structured gap analysis of maintenance and reliability programs
• Benchmark practices against international standards (RCM, TPM, ISO 55000)
• Identify root causes of downtime, high maintenance cost, and inefficiency
• Develop optimization plans to improve reliability, safety, and performance
• Apply KPIs and reliability metrics to monitor improvement progress
Key Benefits of Attending
• Diagnose the weak points in your current maintenance strategy
• Learn global best practices in asset care and equipment reliability
• Build cross-functional alignment around reliability improvement goals
• Reduce unplanned breakdowns and extend asset life
• Use structured tools to move from reactive to proactive maintenance
Intended Audience
This program is designed for:
• Maintenance and reliability engineers
• Plant and operations managers
• Asset integrity and performance specialists
• Engineering and technical supervisors
• Anyone responsible for uptime, safety, or equipment performance
Individual Benefits
Key competencies that will be developed include:
• Maintenance strategy assessment and reliability benchmarking
• Root cause identification and failure prevention
• Use of KPIs and performance indicators (MTBF, MTTR, OEE)
• Optimization of preventive, predictive, and corrective practices
• Planning and executing long-term reliability improvements
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved equipment reliability and uptime
• Lower maintenance costs through better planning and prevention
• Alignment of maintenance practices with business performance goals
• Fewer incidents and increased workforce efficiency
• Stronger asset management compliance with ISO and safety standards
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Framework Briefings – RCM, TPM, ISO 55000, and best practices
• Benchmarking Tools – M&R maturity models and diagnostic checklists
• Case Studies – Asset failures and successful improvement campaigns
• Workshops – Gap analysis, KPIs review, and improvement planning
• Tools & Templates – Reliability scorecards, action plans, audit formats
Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee Breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Introduction to Reliability and Maintenance Best Practices
- Module 1: Defining Maintenance & Reliability Performance (07:30 – 09:30)
• Types of maintenance: reactive, preventive, predictive, and proactive
• Key metrics: MTBF, MTTR, availability, OEE - Module 2: Global Standards and Excellence Models (09:45 – 11:15)
• RCM, TPM, ISO 55000 overview
• Best practice maturity levels and benchmarking - Module 3: Gap Analysis Framework and Process (11:30 – 01:00)
• Step-by-step diagnostic methodology
• Tools for assessment and baseline scoring - Module 4: Workshop – Conduct a Self-Assessment (02:00 – 03:30)
• Evaluate current state of maintenance functions
Day 2: Planning and Scheduling Optimization
- Module 5: Work Management and Job Planning (07:30 – 09:30)
• Planning roles, backlog management, and work order systems
• Standard job plans and BOMs - Module 6: Maintenance Scheduling and Resource Allocation (09:45 – 11:15)
• Weekly, daily, and long-range schedules
• PM compliance and workforce efficiency - Module 7: CMMS and Data Management (11:30 – 01:00)
• Configuration, reporting, and mobile integration
• Using data to drive improvements - Module 8: Workshop – Optimize a Weekly Schedule (02:00 – 03:30)
• Rebuild a sample schedule using best practices
Day 3: Preventive and Predictive Maintenance Strategy
- Module 9: Preventive Maintenance Program Review (07:30 – 09:30)
• Criticality analysis and task effectiveness
• Optimizing PM intervals and coverage - Module 10: Predictive Tools and Condition Monitoring (09:45 – 11:15)
• Vibration, thermography, ultrasound, oil analysis
• Integration into maintenance plans - Module 11: Failure Modes and Risk-Based Approaches (11:30 – 01:00)
• FMEA, risk matrix, and critical asset focus
• RCM light and risk-based inspection - Module 12: Workshop – PM Optimization Scenario (02:00 – 03:30)
• Evaluate and revise a PM strategy
Day 4: Root Cause Analysis and Performance Improvement
- Module 13: Root Cause Failure Analysis (RCFA) Methods (07:30 – 09:30)
• 5 Whys, Fishbone, Fault Tree, and Apollo models
• Linking symptoms to systemic causes - Module 14: Reliability Improvement Campaigns (09:45 – 11:15)
• Targeting chronic failures and bad actors
• Success factors and team alignment - Module 15: KPI Dashboards and Monitoring Tools (11:30 – 01:00)
• Leading vs lagging indicators
• Trend charts, dashboards, and reviews - Module 16: Workshop – Build a Reliability Scorecard (02:00 – 03:30)
• Customize indicators to your plant
Day 5: Culture, Change, and Long-Term Planning
- Module 17: Reliability Culture and Change Management (07:30 – 09:30)
• Leadership, accountability, and workforce buy-in
• Barriers to adoption and solutions - Module 18: Strategic Asset Management Planning (09:45 – 11:15)
• Linking M&R with lifecycle cost and asset strategy
• ISO 55001 asset plans - Module 19: Final Gap Closure and Roadmap Planning (11:30 – 01:00)
• Setting improvement targets and timelines
• Resource planning and budgeting - Module 20: Capstone – Present Your Optimization Plan (02:00 – 03:30)
• Group presentations of action plans
Certification
Participants will receive a Certificate of Completion in Maintenance & Reliability Gap Analysis & Optimization, confirming their ability to evaluate existing maintenance programs, identify improvement opportunities, and implement optimized reliability strategies in line with global standards.