An Intensive 10-day Training Course

Certificate Course in
Creating Maintenance Excellence

Towards a High Added Value of Maintenance

INTRODUCTION TO THE COURSE

Modern industrial organisations are moving decisively away from reactive maintenance models toward proactive strategies that prioritise preventive and predictive planning. This shift is central to achieving Maintenance Excellence — a core element of comprehensive Asset Management. However, despite its importance, many organisations still face challenges in implementing effective maintenance planning processes that unlock true operational value.

The Creating Maintenance Excellence training course is designed to provide professionals with a robust understanding of how to build and sustain world-class maintenance systems. It explores the strategic, technical, and practical dimensions required to reduce downtime, manage costs, enhance safety, and ensure asset performance. Participants will learn to establish a culture of continuous improvement in maintenance practices that deliver measurable value and long-term results.

This comprehensive Creating Maintenance Excellence training course emphasises the integration of planning, performance management, and advanced maintenance technologies. It offers practical insights into how to apply proven methodologies and tools to drive asset reliability, optimise resource utilisation, and align maintenance activities with business goals.

This KC Academy training course will highlight:

  • Implementing Asset Management as a structured foundation for maintenance excellence
  • Using KPIs and balanced scorecards to evaluate and improve maintenance performance
  • Conducting Asset Management maturity assessments and defining improvement roadmaps
  • Building a solid business case for maintenance optimisation through cost-benefit analysis
  • Understanding the principles of Risk-Based Maintenance and managing maintenance-related risks
  • Applying Life Cycle Management strategies including Systems Engineering and RAMS frameworks
  • Implementing Life Cycle Costing for better financial decision-making across the asset lifecycle
  • Adopting modern Predictive and Smart Maintenance approaches to enhance performance
  • Establishing the critical components of an efficient maintenance planning function
  • Accelerating the development of programmed maintenance strategies
  • Planning tasks that meet safety, quality, and operational continuity requirements
  • Coordinating with operations to ensure alignment with maintenance schedules
  • Developing performance indicators to monitor gaps and identify improvement opportunities
  • Minimising equipment defects through structured detection, planning, and execution cycles

This training course is split into two modules:

Module I - Certificate Course in Advanced Maintenance Management

Module II - Certificate Course in Maintenance Planning

Each module is structured and can be taken as a stand-alone training course; however, delegates will maximise their benefits by taking Module 1 and 2 back-to-back as a 2-week training course.

COURSE DETAILS

Objectives Icon

OBJECTIVES

By the end of the Creating Maintenance Excellence training course, participants will be able to:

  • Apply Asset Management principles to guide effective maintenance strategies
  • Identify, analyse, and report on Key Performance Indicators for maintenance operations
  • Evaluate organisational maintenance maturity and define targeted improvement actions
  • Implement Risk-Based Maintenance practices to reduce operational exposure
  • Utilise Systems Engineering and RAMS analysis in Life Cycle Management
  • Calculate Life Cycle Costs and incorporate financial insights into maintenance planning
  • Employ modern Predictive and Smart Maintenance techniques for optimal asset reliability
  • Build foundational master data for successful maintenance operations
  • Drive the development and integration of programmed maintenance processes
  • Create task plans that meet defined safety, efficiency, and quality standards
  • Coordinate logistical support for backlog reduction and maintenance execution
  • Collaborate with stakeholders to produce comprehensive maintenance schedules
  • Generate performance reports that highlight systemic issues and drive resolution
Methodology Icon

TRAINING METHODOLOGY

This Creating Maintenance Excellence training course is a combination of instructor lead topic areas and class discussions. This training course will be conducted along interactive workshop principles. Experiences from different areas will be discussed. There will be many opportunities for discussion and sharing experiences.

Target Audience Icon

WHO SHOULD ATTEND?

This KC Academy training course is suitable to a wide range of professionals involved in the area of creating Maintenance Excellence, but will greatly benefit:

  • All Professionals involved in Maintenance Management
  • Professionals involved in Work Planning & Control (planners, planning engineers)
  • Maintenance Supervisors
  • Maintenance Engineers
  • Maintenance Team Leaders and Managers
  • Operations Team Leaders and Managers

 

DAILY AGENDA

Module 1: Certificate Course in Advanced Maintenance Management
Day 1: Introduction to Asset Management – A Framework for Managing and Optimizing Maintenance
  • Asset Management as a Business Process
  • Asset Management Landscape Model
  • Strategy Framework
    • Line of Sight
    • Asset Management Policy, Asset Management Strategy
    • (Strategic) Asset Management Plan
    • The Position of Maintenance Management
  • Asset Management Roles on Strategic, Tactical and Operational Level
  • ISO 550000 – The International Standard on Asset Management
Day 2: Assessing Asset Management Maturity as A Basis for Maintenance Improvement
  • Measuring Performance
  • Leading & Lagging Indicators – KPI – Dashboards
  • Assessments & Benchmarking against International Standards
  • Asset Management Maturity Assessments
    • Asset Management Workbench (ISO 55000 Gap Analysis)
    • SAM-assessment (ISO 55000 Self-assessment)
  • Determine the Roadmap for Maintenance Improvement
  • The Business Case for Asset Management Improvement – Cost / Benefit Thinking
  • Implementation Aspects
Day 3: Managing Asset Risks – Risk Based Maintenance (RBM)
  • Not every failure is important - the basic principles of risk
  • Risk on business level
  • Risk matrix, risk register
  • Risk on asset level
  • Failure behaviour of systems
  • Choosing the appropriate maintenance tasks for your assets with a Risk Based approach
Day 4: Life Cycle Management
  • Life Cycle Management
    • The Life Cycle of An Asset
    • Demand Forecasting
    • Creation & Acquisition of Assets
      • Systems Engineering Approach
      • RAMS Requirements – Methodologies
  • Life Cycle Costing (LCC)
  • Disposal and/or Replacement - Life Time Extension (Asset Rationalisation)
Day 5: Smart Maintenance
  • Understanding Principles of Predictive Maintenance (PdM)
  • What PdM Technologies to Apply? – A short overview of relevant PdM technologies
  • Smart Maintenance – Measuring Asset Performance with Modern Data Technology
  • Data Analysis Aspects
  • Optimization Aspects – Optimizing the Maintenance Strategy
  • Using Decision Support Tools
Module 2: Certificate Course in Maintenance Planning
Day 6: The Building Blocks of a Modern Maintenance Management System
  • The ‘Asset Healthcare Model’
  • Asset Master Data
  • Organisation Master Data
  • Maintenance Logistics Planning
  • Practical Exercise and Discussion
Day 7: Programmed Maintenance Development and Planning
  • Criticality Grading
  • Failure Modes and Effects Analysis
  • Programmed Task Selection Criteria and Tools
  • CMMS Task Plans and Work Orders
  • Corrective Maintenance Task Procedures
  • Practical Exercise and Discussion
Day 8: Work Management
  • Work Management Process Model
  • Defect Reporting and Notifications
  • Backlog Control
  • Capacity Planning and Resourcing
  • Schedule with Consensus of Stakeholders
  • Practical Exercise and Discussion
Day 9: Shutdown and Turnaround Management
  • Network Planning and Critical Path Scheduling
  • Resource Profile
  • Resource Leveling and Balancing to Optimise the Schedule and Resource Profile
  • Shutdown and Turnaround Progress Tracking and Control
  • Practical Exercise and Discussion
Day 10: Performance Management
  • Setting-up Performance Indicators and Data Sources
  • Work Management Performance Indicators
  • Asset Maintenance Effectiveness Performance Indicators
  • Cost Control Performance Indicators
  • Planning Performance Indicators
  • Practical Exercise and Discussion
Objectives Icon

Certificate

On successful completion of this training course, KC ACademy Certificate will be awarded to the delegates.

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