About This Course
In today's competitive industrial landscape, unplanned equipment failures carry enormous costs — in lost production, safety incidents, emergency repair expenditure, and reputational damage. Organisations that invest in structured, intelligence-driven planned maintenance consistently outperform those that rely on reactive approaches. Industrial Planned Maintenance: Strategies, Systems, and Operational Excellence is designed to bridge the gap between theoretical maintenance frameworks and practical shop-floor implementation.
This course takes participants through the full lifecycle of a world-class maintenance programme — from understanding failure modes and developing preventive schedules, to leveraging condition-monitoring technologies, managing spare parts inventories, and building a culture of continuous improvement. Whether you are refining an existing maintenance system or building one from the ground up, this programme provides the strategic insight and technical know-how to make it work.
Delivered by experienced maintenance engineering practitioners, the course draws on real industrial case studies from manufacturing, utilities, oil and gas, and infrastructure sectors. Participants leave with actionable frameworks, ready-to-use templates, and a clear roadmap for elevating maintenance performance within their own organisations. TrainingComplex's structured, results-focused approach ensures that every concept is grounded in operational reality and immediately applicable on the job.
Who Should Attend
- Maintenance Engineers and Technicians responsible for planning and executing equipment upkeep
- Plant Managers and Operations Managers seeking to reduce downtime and improve asset reliability
- Reliability Engineers developing or improving maintenance strategies for critical plant assets
- Facilities Managers overseeing maintenance programmes in manufacturing, utilities, or infrastructure settings
- Maintenance Planners and Schedulers coordinating preventive and predictive work orders
- HSE Officers involved in maintenance-related safety planning and compliance
- Project Engineers transitioning into maintenance management roles
- Asset Managers responsible for life-cycle cost optimisation and capital planning
Learning Objectives
- Understand the principles and business case for planned maintenance versus reactive and corrective approaches
- Apply Reliability-Centred Maintenance (RCM) and Total Productive Maintenance (TPM) frameworks to industrial contexts
- Develop comprehensive preventive maintenance schedules based on equipment criticality and failure data
- Implement condition monitoring and predictive maintenance techniques including vibration analysis, thermography, and oil analysis
- Design and manage an effective Computerised Maintenance Management System (CMMS) to plan, track, and report maintenance activities
- Optimise spare parts and materials management to minimise stockouts and reduce inventory holding costs
- Conduct Root Cause Analysis (RCA) on equipment failures to prevent recurrence and drive continuous improvement
- Establish maintenance KPIs and performance dashboards to monitor operational effectiveness
- Align maintenance planning with production schedules, safety requirements, and regulatory compliance obligations
- Build a maintenance culture that engages frontline technicians and supports long-term operational excellence
Course Modules
Module 1: Foundations of Industrial Planned Maintenance
- The business case: cost of reactive versus planned maintenance
- Evolution of maintenance philosophies from breakdown to proactive strategies
- Key maintenance types: preventive, predictive, condition-based, and corrective
- Asset criticality classification and its role in maintenance prioritisation
- Legal, regulatory, and safety obligations underpinning maintenance programmes
- Linking maintenance strategy to organisational performance and production goals
Module 2: Reliability-Centred Maintenance (RCM)
- Principles and origins of Reliability-Centred Maintenance
- Functional analysis: identifying what assets must do and their performance standards
- Failure Mode and Effects Analysis (FMEA) methodology and application
- Selecting appropriate maintenance tasks based on failure consequences
- RCM decision logic diagrams and task selection worksheets
- Scaling RCM for small versus large and complex asset portfolios
Module 3: Total Productive Maintenance (TPM)
- The eight pillars of TPM and their operational significance
- Autonomous maintenance: empowering operators to own basic equipment care
- Planned maintenance pillar: structuring preventive activities within TPM
- Overall Equipment Effectiveness (OEE) as the primary TPM performance metric
- Eliminating the six big losses: breakdowns, setup, idling, defects, and more
- Building a TPM culture through cross-functional teams and visual management
Module 4: Developing Preventive Maintenance Schedules
- Equipment inventory and asset register development
- Setting maintenance frequencies using manufacturer data, historical records, and failure patterns
- Creating detailed job plans, task lists, and standard operating procedures
- Seasonal and production-aligned scheduling strategies
- Managing maintenance backlogs and prioritising work order queues
- Reviewing and updating PM schedules using feedback and performance data
Module 5: Condition Monitoring and Predictive Maintenance Technologies
- Overview of predictive maintenance and its financial return on investment
- Vibration analysis: principles, data collection, and interpretation of results
- Thermographic inspection: identifying thermal anomalies in electrical and mechanical systems
- Oil and lubricant analysis: contamination, viscosity, and wear particle assessment
- Ultrasound testing and non-destructive testing (NDT) techniques
- Integrating condition monitoring data into maintenance decision-making workflows
Module 6: Computerised Maintenance Management Systems (CMMS)
- Core functions of a CMMS: asset management, work orders, scheduling, and reporting
- Configuring an asset hierarchy and equipment master records
- Creating, assigning, and closing preventive and corrective work orders
- Using CMMS data for maintenance planning and resource allocation
- Generating maintenance reports, history logs, and compliance documentation
- Selecting and implementing a CMMS: key considerations and common pitfalls
Module 7: Spare Parts and Materials Management
- Classifying spare parts by criticality, lead time, and failure frequency
- Determining optimal stock levels using min-max and reorder point strategies
- Managing fast-moving, slow-moving, and capital spare inventories
- Supplier partnerships, vendor-managed inventory, and procurement alignment
- Warehouse organisation and parts kitting for planned maintenance jobs
- Reducing obsolescence and controlling inventory costs without risking availability
Module 8: Root Cause Analysis and Failure Investigation
- Purpose and scope of Root Cause Analysis in maintenance management
- The 5-Why technique: structured questioning to uncover systemic causes
- Fishbone (Ishikawa) diagram for multi-factor failure investigation
- Fault tree analysis for complex, safety-critical failure scenarios
- Documenting findings and implementing corrective and preventive actions (CAPA)
- Building a failure knowledge database to prevent recurrence across the plant
Module 9: Maintenance KPIs, Performance Measurement, and Reporting
- Defining the right KPIs for maintenance: availability, MTBF, MTTR, and cost metrics
- Designing a maintenance performance dashboard for operational and management audiences
- Using trend analysis to identify deteriorating assets and emerging failure patterns
- Benchmarking maintenance performance against industry standards
- Reporting maintenance outcomes to senior leadership and stakeholders
- Continuous improvement cycles: PDCA applied to maintenance performance management
Module 10: Building a Culture of Maintenance Excellence
- Leadership's role in championing maintenance as a strategic business function
- Engaging and upskilling frontline technicians through competency frameworks
- Standardising maintenance practices through SOPs, visual aids, and audits
- Change management techniques for transitioning from reactive to planned maintenance
- Integrating maintenance planning with production, safety, and capital planning teams
- Developing a 90-day maintenance improvement roadmap and sustaining momentum
Requirements & Prerequisites
Participants should have a working background in engineering, maintenance, or plant operations, typically at a technician, engineer, or supervisory level. Basic familiarity with industrial equipment and facility management practices is expected. No prior formal training in maintenance management frameworks is required, though some exposure to maintenance scheduling or CMMS tools will be beneficial.
Training Methodology
- Facility audit simulation exercise where participants assess a fictitious plant's current maintenance practices against world-class benchmarks
- Case study analysis drawn from real industrial failures in manufacturing, oil and gas, and utilities sectors to illustrate the cost of poor maintenance planning
- Hands-on CMMS workshop using a live demo environment to create work orders, maintenance schedules, and asset registers
- Small-group RCM analysis exercise in which teams apply failure mode and effects analysis (FMEA) to a set of critical assets
- Condition monitoring demonstration sessions covering vibration data interpretation, thermal imaging, and oil sample reports
- KPI dashboard design workshop where participants construct a maintenance scorecard aligned to their organisation's strategic objectives
- Root Cause Analysis role-play using the 5-Why and fishbone diagram techniques on realistic failure scenarios
- Peer-to-peer knowledge exchange sessions allowing delegates from different industries to share maintenance challenges and solutions
- Action planning workshop at the close of the programme, where each participant drafts a 90-day maintenance improvement plan for their own organisation
Organisational Benefits
- Significant reduction in unplanned downtime and its associated production losses and emergency costs
- Extended equipment life cycles resulting in deferred capital expenditure and improved return on assets
- Improved workplace safety through systematic identification and mitigation of maintenance-related hazards
- Enhanced regulatory compliance with documented, auditable maintenance records and procedures
- Stronger interdepartmental collaboration between maintenance, operations, procurement, and finance teams
- Data-driven decision-making enabled by properly configured CMMS platforms and performance dashboards
- Reduced spare parts expenditure through smarter inventory management and demand forecasting
- A structured pipeline of maintenance competency within the workforce, reducing dependency on ad hoc expertise
- Higher equipment availability and reliability, directly supporting production targets and customer commitments
Where Is Industrial Planned Maintenance: Strategies, Systems, and Operational Excellence Training Offered?
This course runs in-person across: Dubai, Kigali, Riyadh, Mombasa, Lagos, Nairobi, Nakuru, Zanzibar, Abuja, Cape Town, Dar es Salaam, Kampala, Naivasha, Kisumu, Accra, Pretoria, Addis Ababa, Arusha, Johannesburg, plus Live Virtual (online) cohorts. Browse live dates for your city below.
Upcoming Schedules
| Location | Format | Dates | Price |
|---|
| Live Virtual |
Online |
19 Oct 2026 – 23 Oct 2026 |
KES 80,000 |
| Live Virtual |
Online |
24 Oct 2026 – 15 Nov 2026 |
KES 80,000 |
| Dubai, United Arab Emirates |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 4,100 |
| Kigali, Rwanda |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 1,900 |
| Riyadh, Saudi Arabia |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 4,500 |
| Mombasa, Kenya |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
KES 120,000 |
| Lagos, Nigeria |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 2,500 |
| Nairobi, Kenya |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
KES 115,000 |
| Nakuru, Kenya |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
KES 120,000 |
| Zanzibar, Tanzania |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 2,500 |
| Abuja, Nigeria |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 2,800 |
| Cape Town, South Africa |
In-Person |
26 Oct 2026 – 30 Oct 2026 |
USD 3,800 |
| Dubai, United Arab Emirates |
In-Person |
2 Nov 2026 – 6 Nov 2026 |
USD 4,100 |
| Dar es Salaam, Tanzania |
In-Person |
2 Nov 2026 – 6 Nov 2026 |
USD 2,300 |
| Nairobi, Kenya |
In-Person |
2 Nov 2026 – 6 Nov 2026 |
KES 105,000 |
+228 more dates — view live schedule →
Frequently Asked Questions
Do I need formal engineering qualifications to attend this course?
Formal qualifications are not required. The course is designed for professionals with practical experience in maintenance, operations, or engineering roles. A working familiarity with industrial equipment and plant environments is sufficient to benefit fully from the programme.
Will participants receive a certificate upon completion?
Yes. Participants who attend the full programme will receive a TrainingComplex Certificate of Completion in Industrial Planned Maintenance: Strategies, Systems, and Operational Excellence. This certificate recognises the professional development achieved and can be included in your portfolio or CPD records.
Is the course relevant to a specific industry, or does it apply across sectors?
The course is deliberately cross-sectoral and draws case studies from manufacturing, oil and gas, utilities, infrastructure, and facilities management. The maintenance principles, frameworks, and tools covered are applicable wherever physical assets require systematic upkeep.
Will we work with a live CMMS platform during the course?
Yes. A hands-on CMMS workshop session is included, using a live demonstration environment where participants practice creating asset records, work orders, and maintenance schedules. This practical exposure reinforces the theoretical concepts and builds immediate workplace confidence.
Can my organisation send a team to this course?
Absolutely. TrainingComplex welcomes team bookings and can also deliver this programme as a dedicated in-house course at your facility, customised to your specific assets, maintenance systems, and operational context. Contact us for group pricing and in-house delivery options.
