Ask any plant manager what keeps them up at night, and unplanned downtime — or worse, a safety incident — is usually near the top of the list. This Training Course from the Arab British Fellowship Training Academy builds the technical and managerial skills maintenance teams need to move beyond fire-fighting: recognising which maintenance approach fits each situation, and applying it before failures turn into costly interruptions.

The programme covers how planning, execution, and follow-up come together across preventive, corrective, and predictive maintenance in industrial environments, and traces how maintenance concepts have evolved to meet the daily challenges maintenance teams actually face. Participants finish with the decision-making skills to optimise maintenance strategy, cut downtime, and support long-term operational excellence — safely.

Who Should Attend?

• Maintenance engineers and technicians working in industrial facilities.
• Production managers and supervisors overseeing manufacturing lines.
• Planners, coordinators, consultants, and asset management specialists.

Knowledge and Benefits:

By the end of the programme, participants will be able to:

• Identify different types of industrial maintenance systems and the principles behind applying each one.
• Integrate preventive, corrective, and predictive maintenance into a single coherent strategy.
• Plan maintenance effectively based on facility needs and prioritise tasks by risk and impact.
• Evaluate equipment performance and apply best practices that reduce maintenance costs.
• Build a safety-first culture that protects teams while keeping equipment running.

Module 1: Why Maintenance Strategy Matters

• The operational and economic impact of equipment downtime.
• How maintenance connects to product quality and asset efficiency.
• Sudden versus chronic failures, and classifying failures by cause and impact.

Module 2: Organising the Maintenance Function

• Planned versus unplanned maintenance, and distributing roles within the technical team.
• Managing maintenance records, outcomes, and documentation.
• Early detection methods that catch faults before they escalate.

Module 3: Corrective Maintenance — When Failure Comes First

• Definitions, advantages, and risks of relying on corrective maintenance alone.
• Diagnosing root causes accurately and executing rapid technical repairs.
• Resourcing corrective work: flexible team management and emergency supplies.

Module 4: Preventive Maintenance by Design

• Core concept, triggers, and how preventive differs from corrective maintenance.
• Building regular schedules, prioritising high-value equipment, and using manufacturer guidelines.
• Measuring preventive performance by comparing failure rates before and after implementation.

Module 5: Predictive and Condition-Based Maintenance

• Definition, purpose, and how predictive maintenance differs from preventive approaches.
• Tools for fault prediction: vibration and noise analysis, thermal imaging, and digital sensors.
• Reading indicators, interpreting data, and monitoring via SCADA and PLC systems.

Module 6: Planning, Scheduling and Spare Parts

• Determining optimal downtime windows and aligning schedules with operations, including CMMS tools.
• Identifying critical spare parts, storage priorities, and inventory-versus-downtime cost trade-offs.
• Logistics cost analysis and smart purchasing strategies.

Module 7: Measuring and Improving Performance

• Key indicators: MTBF, MTTR, availability, and cost-related KPIs.
• Collecting and analysing performance data to spot recurring failure causes.
• Turning indicators into strategic decisions and resource allocation.

Module 8: Safety and Total Productive Maintenance (TPM)

• Electrical and mechanical risks, and procedures for handling critical failures safely.
• Safety systems, PPE selection, and building a safety culture across teams.
• TPM principles — zero breakdowns, zero downtime — and maintenance as a strategic, competitive tool.