Maintenance and Reliability Management

Programme Summary

Maintenance leaders must connect equipment reliability, work execution and investment decisions to business priorities. This programme develops an integrated approach to maintenance strategy, asset performance, team capability and cost control. Participants evaluate a realistic plant case, challenge unreliable performance measures and construct a practical improvement roadmap with clear ownership, resource requirements and evidence for management review.

Training Objectives

1 Connect maintenance strategy with business objectives; 2 Strengthen reliability and asset lifecycle decisions; 3 Improve planning execution and workforce coordination; 4 Develop meaningful maintenance performance management; 5 Build a prioritised reliability improvement roadmap.

Learning Outcomes

1 Assess maintenance maturity using case evidence; 2 Prioritise assets by consequence and performance; 3 Select appropriate maintenance and reliability strategies; 4 Evaluate work management and cost indicators; 5 Defend a resourced improvement roadmap.

Target Audience

Maintenance Managers; Reliability Managers; Engineering Managers; Operations Managers; Asset Managers; Maintenance Superintendents.

Target Industries

Process Manufacturing; Power Generation; Petrochemicals; Water Utilities; Mining; Transport Infrastructure.

Course Contents

• Module 1 Business Alignment: Asset contribution to business outcomes; Maintenance objectives and service expectations; Risk cost and performance tradeoffs.
• Module 2 Maintenance Organisation: Roles interfaces and decision rights; Centralised and distributed delivery models; Operations maintenance and engineering collaboration.
• Module 3 Asset Information: Asset hierarchy and equipment identification; Technical records and configuration control; Data completeness and ownership responsibilities.
• Module 4 Criticality and Risk: Failure consequences and exposure criteria; Asset criticality assessment and prioritisation; Safety environmental and production constraints.
• Module 5 Failure Behaviour: Failure modes and degradation mechanisms; Repeat failures and chronic losses; Evidence quality and analytical limitations.
• Module 6 Maintenance Strategy Selection: Preventive predictive and corrective approaches; Task applicability and effectiveness tests; Run to failure decision boundaries.
• Module 7 Reliability Analysis: Failure history and reliability measures; Availability maintainability and downtime interpretation; Screening data before statistical conclusions.
• Module 8 Condition Monitoring Integration: Monitoring coverage and diagnostic capability; Findings escalation and maintenance decisions; Programme effectiveness and specialist interfaces.
• Module 9 Work Identification: Operator observations and defect reporting; Scope quality and priority assignment; Emergency work and backlog control.
• Module 10 Planning and Job Preparation: Task steps resources and materials; Job plans estimates and technical references; Safety prerequisites and execution readiness.
• Module 11 Scheduling and Coordination: Capacity constraints and weekly schedules; Operations windows and schedule protection; Breakin work and priority governance.
• Module 12 Work Execution Quality: Supervision workmanship and technical standards; Permits isolation and competent teams; Testing restoration and acceptance evidence.
• Module 13 Materials and Contractors: Critical spares and inventory decisions; Contractor capability and service performance; Warranty repair and supplier learning.
• Module 14 Cost and Budget Control: Labour materials contracts and lifecycle costs; Budget forecasts and variance analysis; Financial justification of improvement actions.
• Module 15 Workforce Capability: Competence needs and practical development; Knowledge transfer and succession risks; Team engagement and performance conversations.
• Module 16 Performance Measurement: Leading and lagging maintenance indicators; Denominator consistency and data quality; Balanced measures and gaming prevention.
• Module 17 Root Cause and Improvement: Trigger criteria and evidence preservation; Corrective action ownership and verification; Learning across equipment and sites.
• Module 18 Lifecycle and Investment Decisions: Maintain replace or redesign options; Obsolescence risks and lifecycle costs; Capital project maintenance requirements.
• Module 19 Management Review: Performance trends risks and resource needs; Governance decisions and accountability records; Improvement portfolio and benefit tracking.
• Module 20 Integrated Improvement Roadmap: Diagnosing a supplied plant situation; Prioritising actions resources and milestones; Presenting a defensible reliability business case.

Assessment

• 100 single best answer questions, including applied scenarios; one mark per question.
• 150 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied reference pack permitted; external internet and AI assistance prohibited.
• Individual applied assessment (90 minutes): Develop a maintenance improvement roadmap for a supplied plant, including criticality priorities, work management changes, performance measures, resources and a justified investment recommendation.
• Assessment criteria: Integration of risk performance and cost; Practicality of work management improvements; Quality of roadmap evidence and prioritisation.
• Pass each component separately: 75/100 written marks (75%) and at least 70% on the applied task.
• All mandatory criteria must pass: Do not accept unresolved intolerable safety or environmental risks.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed maintenance and reliability management skills; professional certification, specialist authority and employer appointments remain separate.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

555

Total teaching hoursTotal teaching hoursTotal teaching hours

35 hours; breaks, pre course work and formal final assessments excluded.35 hours; breaks, pre course work and formal final assessments excluded.35 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

At least two years of maintenance, engineering or operations experience is recommended. Familiarity with work orders, equipment failures and maintenance costs is required.At least two years of maintenance, engineering or operations experience is recommended. Familiarity with work orders, equipment failures and maintenance costs is required.At least two years of maintenance, engineering or operations experience is recommended. Familiarity with work orders, equipment failures and maintenance costs is required.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Complete a 45 minute maintenance maturity diagnostic using the supplied plant profile and performance dashboard.Complete a 45 minute maintenance maturity diagnostic using the supplied plant profile and performance dashboard.Complete a 45 minute maintenance maturity diagnostic using the supplied plant profile and performance dashboard.

End of course assessmentEnd of course assessmentEnd of course assessment

100 question written exam (150 minutes) and individual applied task (90 minutes).100 question written exam (150 minutes) and individual applied task (90 minutes).100 question written exam (150 minutes) and individual applied task (90 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.