OPERATOR MAINTENANCE, PREVENTATIVE MAINTENANCE & INSPECTION TECHNIQUES
Building Maintenance Ownership and Reliability Through Daily Inspections, Early Detection, and Operator Involvement”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 27 – 29 Jan 2025 | Kuala Lumpur, Malaysia | USD 2495 per delegate |
| 28 – 30 Apr 2025 | Dubai, UAE | USD 2495 per delegate |
| 27 – 29 May 2025 | Doha, Qatar | USD 2495 per delegate |
| 01 – 03 Jul 2025 | Muscat, Oman | USD 2495 per delegate |
| 28 – 30 Oct 2025 | Manama, Bahrain | USD 2495 per delegate |
Course Introduction
Operator and preventative maintenance are the first lines of defense against unplanned downtime and costly repairs. Empowering equipment operators to inspect, detect, and carry out routine maintenance creates a culture of shared responsibility and improves equipment reliability.
This 3-day course equips maintenance, operations, and production staff with the skills to perform preventative tasks and inspections safely and effectively. Through practical examples and structured frameworks, participants will learn how to detect early warning signs, reduce breakdowns, and improve coordination with maintenance teams.
Course Objectives
By the end of this course, participants will be able to:
- Perform daily and periodic equipment inspections effectively
- Identify signs of wear, misalignment, leaks, and unsafe conditions
- Conduct basic maintenance tasks such as lubrication and adjustments
- Record findings and report faults using standard procedures
- Support preventative maintenance programs with accuracy and discipline
- Collaborate with maintenance teams to reduce failures and extend equipment life
Key Benefits of Attending
- Improve equipment uptime and reduce downtime due to undetected faults
- Develop ownership and accountability among machine operators
- Reduce costs by addressing small issues before they escalate
- Strengthen collaboration between operations and maintenance
- Learn structured inspection and reporting techniques for reliability
Intended Audience
This program is designed for:
- Machine and equipment operators
- Line supervisors and shift leaders
- Maintenance technicians and mechanics
- Production and operations team members
- Safety and quality officers involved in reliability improvement
Individual Benefits
Key competencies that will be developed include:
- Visual and functional inspection techniques
- Basic maintenance task execution
- Fault detection and early warning recognition
- Equipment cares routines and safe practices
- Communication and coordination with maintenance teams
Organization Benefits
Upon completing the training course, participants will demonstrate:
- Detect equipment issues early and reduce failure frequency
- Increase equipment availability and productivity
- Promote cross-functional ownership of plant assets
- Improve safety, compliance, and cleanliness standards
- Reduce maintenance costs and response time
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
- Hands-on demonstrations and maintenance simulations
- Visual inspection toolkits and checklists
- Video-based analysis of common fault symptoms
- Case studies from industrial plants
- Group activities and job task walkthroughs
Course Outline
Detailed 3-Day 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: Maintenance Fundamentals and Operator Roles
Module 1: Introduction to Operator Maintenance (07:30 – 09:30)
- The role of operators in asset reliability
- Maintenance types: corrective, preventative, predictive
- Safety, responsibility, and ownership
Module 2: Equipment Basics and Failure Modes (09:45 – 11:15)
- Understanding components: bearings, belts, seals, fasteners
- Common failure causes: wear, misalignment, overloading
- Early detection benefits
Module 3: Visual and Functional Inspections (11:30 – 01:00)
- What to look for: leaks, noise, vibration, temperature, contamination
- Functional checks for operation consistency
- Tools and techniques for effective inspection
Module 4: Simulation – Daily Inspection Walkthrough (02:00 – 03:30)
- Teams simulate a line-side inspection using real-world checklists
Day 2: Preventative Maintenance & Care Techniques
Module 5: Preventative Maintenance Procedures (07:30 – 09:30)
- Cleaning, lubricating, tightening, adjusting
- Lubrication basics and handling best practices
- Filters, fasteners, hoses, and belt checks
Module 6: Documentation and Reporting (09:45 – 11:15)
- Using logbooks, tags, and mobile apps
- Communicating with technicians and escalation protocol
- Capturing trends and recurring issues
Module 7: Operator-Maintenance Collaboration (11:30 – 01:00)
- Roles and boundaries in autonomous maintenance
- Partnering with maintenance technicians
- Total Productive Maintenance (TPM) overview
Module 8: Hands-On – Preventative Task Practice (02:00 – 03:30)
- Participants practice greasing, bolt checking, and leak inspection (mock/simulated)
Day 3: Inspection Routines, Case Studies, and Implementation
Module 9: Creating Inspection Standards and Routines (07:30 – 09:30)
- Developing standard inspection tasks
- Defining frequency and sequencing
- Adapting routines to machine types
Module 10: Root Cause Awareness and Fault Prevention (09:45 – 11:15)
- Linking inspection findings to root causes
- Examples of faults that were preventable
- Escalation vs. intervention decision-making
Module 11: Building a Daily Equipment Care Culture (11:30 – 01:00)
- 5S for machines and inspection points
- Visual management and improvement boards
- Recognition and feedback systems
Module 12: Final Workshop – Operator Care Action Plan (02:00 – 03:30)
- Participants develop a practical inspection and care checklist
- Presentations, peer feedback, and course wrap-up
Certification
Participants will receive a Certificate of Completion in Operator Maintenance, Preventative Maintenance & Inspection Techniques, recognizing their ability to safely support reliability programs through structured care, inspection, and collaboration.