Maintenance & Supervision Training Course

1. Introduction to Maintenance Management

1.1 Maintenance Management Fundamentals

• Maintenance types including (reactive maintenance, preventive maintenance, predictive maintenance, and reliability-centered maintenance)

• Asset management principles including (asset lifecycle management, performance optimization, risk assessment, and value creation)

• ISO 55000 framework including (asset management systems, organizational context, leadership requirements, and performance evaluation)

• Maintenance objectives including (equipment reliability, cost optimization, safety compliance, and operational efficiency)

1.2 Supervisory Responsibilities

• Maintenance supervisor role including (planning coordination, resource management, team leadership, and performance monitoring)

• Organizational structure including (maintenance hierarchy, reporting relationships, authority delegation, and accountability systems)

• Stakeholder management including (operations coordination, engineering liaison, contractor management, and vendor relations)

• Performance expectations including (productivity targets, quality standards, safety requirements, and cost control)

2. Maintenance Planning and Scheduling

2.1 Work Planning Optimization

• Planning process including (work identification, job planning, resource estimation, and material procurement)

• Work order management including (request processing, priority assignment, resource allocation, and progress tracking)

• API RP 580 guidelines including (risk-based inspection, integrity management, fitness-for-service, and optimization strategies)

• Planning tools including (CMMS systems, planning software, resource databases, and scheduling applications)

2.2 Scheduling and Resource Management

• Scheduling techniques including (priority systems, resource leveling, capacity planning, and workflow optimization)

• Resource coordination including (personnel scheduling, equipment allocation, material availability, and contractor coordination)

• Efficiency optimization including (schedule compliance, backlog management, resource utilization, and productivity improvement)

• Performance metrics including (schedule adherence, wrench time, planned work percentage, and cost variance)

3. Team Leadership and Human Resource Development

• Leadership principles including (communication skills, motivation techniques, conflict resolution, and team building)

• Workforce development including (training programs, skill development, competency assessment, and career planning)

• Performance management including (goal setting, performance evaluation, feedback delivery, and recognition programs)

• Change management including (process improvement, technology adoption, organizational change, and resistance management)

4. Asset Reliability and Condition Monitoring

4.1 Reliability Engineering Applications

• Reliability concepts including (failure analysis, failure modes, reliability metrics, and availability calculations)

• Condition monitoring techniques including (vibration analysis, thermography, oil analysis, and ultrasonic testing)

• Predictive maintenance technologies including (sensor systems, data analytics, trend analysis, and diagnostic tools)

• Root cause analysis including (failure investigation, problem-solving methodologies, corrective actions, and prevention strategies)

4.2 Equipment Optimization Strategies

• Equipment lifecycle management including (procurement planning, installation oversight, operational support, and retirement planning)

• Modification and upgrade planning including (technology assessment, cost-benefit analysis, implementation planning, and performance validation)

• Spare parts management including (inventory optimization, critical spares identification, procurement strategies, and storage management)

• Vendor management including (supplier evaluation, contract negotiation, performance monitoring, and relationship management)

5. Maintenance Cost Management and Budget Planning

• Cost analysis including (direct costs, indirect costs, lifecycle costs, and total cost of ownership)

• Budget development including (budget preparation, cost forecasting, resource planning, and variance analysis)

• Cost control measures including (expenditure monitoring, approval processes, cost reduction initiatives, and efficiency improvement)

• Economic justification including (return on investment, net present value, payback analysis, and risk assessment)

6. Quality Assurance and Documentation Management

6.1 Quality Management Systems

• Quality standards including (quality control procedures, inspection requirements, acceptance criteria, and non-conformance management)

• Documentation systems including (work procedures, technical manuals, inspection records, and compliance documentation)

• Audit management including (internal audits, external audits, compliance verification, and corrective action tracking)

• Continuous improvement including (quality metrics, process improvement, best practice development, and knowledge management)

6.2 Regulatory Compliance and Safety Management

• OSHA 29 CFR 1910 requirements including (general industry standards, maintenance safety, lockout/tagout, and confined space entry)

• Safety management including (hazard identification, risk assessment, safety procedures, and incident prevention)

• Environmental compliance including (waste management, emission control, spill prevention, and regulatory reporting)

• Training and competency including (safety training, skills certification, competency assessment, and record keeping)

7. Technology Integration and Digital Maintenance

• CMMS implementation including (system selection, configuration, data migration, and user training)

• Digital technologies including (mobile applications, IoT sensors, artificial intelligence, and predictive analytics)

• Data management including (data quality, data analysis, reporting systems, and decision support)

• Technology adoption including (change management, training programs, performance monitoring, and continuous improvement)

8. Performance Measurement and Continuous Improvement

• Key performance indicators including (equipment uptime, maintenance costs, work order completion, and safety metrics)

• Benchmarking including (industry standards, best practices, performance comparison, and improvement opportunities)

• Continuous improvement including (lean maintenance, process optimization, waste elimination, and efficiency enhancement)

• Innovation management including (technology adoption, process innovation, employee suggestions, and improvement implementation)