A large share of early equipment failures after a plant startup can be traced back to one thing: maintenance wasn't actually ready when operations began. Spare parts hadn't arrived, the CMMS wasn't loaded with accurate asset data, or job plans existed only on paper. This course walks maintenance, reliability, and operations teams through a practical method for making sure maintenance systems, people, and resources are genuinely ready before equipment is energised or handed over.

Delivered by Arab British Fellowship Training Academy as part of its Operations Readiness and Assurance Training courses within the Engineering maintenance and operation category, the course covers CMMS preparation, spare parts availability, preventive maintenance planning, asset records, and the coordination needed between maintenance, operations, engineering, and commissioning teams.

By the end of this course, participants will be able to:

• Recognise the warning signs of poor maintenance readiness and the operational risk they create after startup.
• Assess maintenance readiness for new, modified, or existing facilities against a structured framework.
• Establish equipment criticality, maintenance priorities, and an effective pre-startup maintenance strategy.
• Prepare and validate preventive and predictive maintenance programmes ahead of handover.
• Configure and verify asset data, equipment hierarchy, and job plans within a CMMS.
• Confirm the availability of critical spare parts, tools, and maintenance resources before startup.
• Review maintenance procedures and technical documentation for completeness and accuracy.
• Coordinate maintenance requirements with commissioning and operations teams to close readiness gaps.
• Establish reliability and maintainability requirements before assets are handed over.
• Support a controlled, well-documented transition from project execution to routine maintenance.

Who Should Attend

• Maintenance engineers, planners, and supervisors.
• Reliability engineers and managers.
• Mechanical, electrical, and instrumentation engineers.
• Commissioning and startup engineers.
• Operations and production personnel.
• Project engineers and managers.
• Asset integrity professionals.
• Turnaround and shutdown specialists.
• Operations readiness and assurance personnel.
• Engineering and technical support staff.

Module 1: When Maintenance Isn't Ready, Risks and Warning Signs

• Common consequences of poor maintenance readiness.
• Maintenance requirements before startup.
• Relationship between commissioning, startup and maintenance.
• Roles, responsibilities and readiness milestones.

Module 2: Building the Maintenance Readiness Plan

• Developing a maintenance readiness plan and assessment framework.
• Maintenance deliverables and documentation.
• Resource and competency planning.
• Workload forecasting, readiness tracking and reporting.

Module 3: Asset and Equipment Readiness

• Equipment identification and asset hierarchy.
• Equipment criticality assessment and maintainability requirements.
• Equipment data verification.
• Maintenance access, isolation and inspection requirements.

Module 4: Maintenance Strategy and CMMS Readiness

• Developing an asset-based maintenance strategy.
• Preventive, predictive and condition-based maintenance.
• Reliability-centred maintenance principles and failure modes.
• CMMS implementation, asset master data and task lists.

Module 5: Spare Parts, Tools and Materials Readiness

• Identifying and managing critical spare parts.
• Materials and inventory planning.
• Special tools, warehouse and storage requirements.
• Verifying parts availability before startup.

Module 6: Maintenance Procedures and Work Management

• Developing maintenance procedures, job plans and work instructions.
• Permit-to-work interfaces and isolation requirements.
• Maintenance planning, scheduling and equipment handover.
• Safe maintenance execution during startup.

Module 7: Reliability and Asset Performance Readiness

• Reliability objectives and risks before startup.
• Maintainability and availability considerations.
• Performance monitoring and reliability data collection.
• Early-life equipment failure management.

Module 8: Maintenance Handover and Final Verification

• Maintenance handover from projects to operations.
• Punch-list management and outstanding actions.
• Documentation, certification, preservation and pre-startup maintenance.
• Final maintenance readiness verification.

Module 9: Maintenance Readiness Assurance and Continuous Improvement

• Maintenance readiness audits and indicators.
• Gap identification and corrective actions.
• Risk-based readiness assessment and final reviews.
• Continuous improvement after startup.