TOTAL PLANT MAINTENANCE
“Maximizing Plant Availability and Asset Efficiency through an Integrated Maintenance Strategy”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 04 – 07 Mar 2025 | Dubai, UAE | USD 2995 per delegate |
Course Introduction
A plant is only as reliable as its weakest asset. Total Plant Maintenance (TPM) is a comprehensive, systematic approach to achieving world-class reliability, availability, and performance across the entire facility. It encompasses all maintenance strategies—from preventive and predictive to reliability-centered and operator-driven maintenance.
This intensive 4-day course empowers participants with the tools, techniques, and strategic insights to build and sustain a Total Plant Maintenance culture. Participants will learn how to optimize equipment life cycles, reduce downtime, improve team performance, and embed continuous improvement across maintenance operations.
Course Objectives
By the end of this course, participants will be able to:
- Understand the principles and pillars of Total Plant Maintenance
- Develop and implement a site-wide maintenance strategy
- Apply RCM, PM, PdM, and CM techniques across the asset base
- Reduce equipment failures through structured planning and root cause analysis
- Establish KPIs for performance monitoring and maintenance effectiveness
- Foster a collaborative culture between maintenance and operations
Key Benefits of Attending
- Move from reactive to proactive maintenance culture
- Build plant-wide maintenance ownership and accountability
- Reduce unplanned downtime and improve equipment reliability
- Use data-driven insights to optimize maintenance decisions
- Strengthen alignment between production, engineering, and maintenance teams
Intended Audience
This program is designed for:
- Maintenance managers, engineers, and supervisors
- Reliability and asset management professionals
- Plant and operations managers
- Maintenance planners and CMMS specialists
- Continuous improvement and TPM coordinators
Individual Benefits
Key competencies that will be developed include:
- TPM framework implementation
- Asset criticality analysis and risk-based maintenance
- Planning and scheduling optimization
- CMMS utilization and data reporting
- Maintenance cost control and lifecycle extension
Organization Benefits
Upon completing the training course, participants will demonstrate:
- Greater equipment uptime and reduced lifecycle costs
- A structured and unified plant maintenance strategy
- Improved compliance with regulatory and safety standards
- More effective cross-functional collaboration and communication
- Enhanced culture of reliability and continuous improvement
Instructional Methdology
- Strategy Briefings – TPM frameworks, maintenance optimization, and cross-functional integration
- Hands-On Exercises – Criticality ranking, failure analysis, maintenance matrix development
- Case Studies – Global TPM implementations in manufacturing and process industries
- Workshops – Planning/scheduling simulations, KPI design, improvement action planning
- Peer Exchange – Discussion of implementation challenges and successes
- Tools – TPM audit checklist, planning templates, downtime logs, performance dashboards
Course Outline
Detailed 2-Day Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 2–3 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
DAY 1 – TPM Strategy and Implementation Foundations
Module 1: Introduction to Total Plant Maintenance
- Principles of TPM and how it differs from traditional maintenance
- The eight pillars of TPM
- TPM success factors and implementation phases
Module 2: Maintenance Strategy Maturity Model
- Evolution from reactive to proactive maintenance
- Assessing your current maturity level
- TPM benchmarking and readiness check
Module 3: Asset Criticality and Equipment Classification
- Ranking assets based on failure impact
- Prioritizing maintenance strategies accordingly
- Creating an equipment strategy matrix
Module 4: Workshop – TPM Readiness Assessment & Planning
- Teams assess current plant status and define vision for TPM
DAY 2 – Maintenance Planning, PM & PdM Integration
Module 5: Preventive and Predictive Maintenance Systems
- Optimizing PM schedules using FMEA and usage data
- Selecting and implementing PdM technologies
- Task standardization and lubrication management
Module 6: Maintenance Planning and Scheduling
- Planning workflow: request to execution
- Job planning templates, BOMs, and work orders
- Weekly scheduling, backlog management, and priorities
Module 7: Autonomous Maintenance and Operator Involvement
- Role of operators in equipment care
- Standard inspection tasks and TPM checklists
- Visual management and 5S foundations
Module 8: Workshop – PM Optimization and Schedule Design
- Teams design a PM plan for critical equipment
DAY 3 – Reliability Tools and Failure Management
Module 9: Root Cause Analysis and Failure Prevention
- Using 5 Whys, Fishbone, and Fault Tree Analysis
- Common failure modes and detection techniques
- Integrating RCA into a continuous improvement loop
Module 10: Reliability-Centered Maintenance (RCM) Essentials
- Identifying functional failures and consequences
- Building RCM templates for rotating and static equipment
- Bridging RCM outputs into CMMS
Module 11: Measuring Maintenance Performance
- MTTR, MTBF, and OEE explained
- Linking work orders to KPIs and dashboards
- Using downtime and wrench time data for insights
Module 12: Workshop – RCA Simulation and KPI Design
- Participants solve a plant failure and develop KPI metrics
DAY 4 – Implementation, Culture & Continuous Improvement
Module 13: Maintenance Culture and Team Development
- Role of leadership and front-line teams in TPM
- Maintenance skills matrix and training planning
- Building accountability and engagement
Module 14: CMMS and Technology Integration
- CMMS best practices for planning and analysis
- Digital tools for inspections and mobile execution
- Integration with production and procurement systems
Module 15: TPM Audits and Continuous Improvement Cycles
- Designing TPM audits and plant walkthroughs
- Action logs, A3 reports, and Kaizen follow-up
- Aligning TPM with ISO 55000 and EAM strategies
Module 16: Final Workshop – TPM Roadmap Development
- Teams build a phased implementation plan
- Instructor feedback and discussion on next steps
Certification
Participants will receive a Certificate of Completion in Total Plant Maintenance, demonstrating their capability to plan, implement, and sustain a high-performing TPM strategy.