Upon successful completion, participants will be able to:

1. Define and calculate 18+ key reliability KPIs using SMRP standards
2. Design and implement a comprehensive benchmarking program
3. Collect, validate, and normalize reliability data
4. Analyze performance gaps and identify improvement opportunities
5. Develop effective KPI dashboards for different audiences
6. Create action plans for reliability improvement
7. Communicate benchmarking results to stakeholders
8. Establish continuous improvement monitoring systems
9. Apply industry best practices and world-class standards
10. Align reliability metrics with business objectives

• Reliability Engineers and Managers
• Maintenance Managers and Supervisors
• Asset Management Professionals
• Plant Managers and Operations Leaders
• CMRP/CMRT Certification Candidates
• Continuous Improvement Specialists
• Engineering Managers in Oil & Gas, Manufacturing, and Process Industries

Day 1: Foundation & Metrics

Session 1 : Introduction to Reliability KPIs and Benchmarking

• Definition of reliability and maintainability
• Role of KPIs in driving operational excellence
• Overview of benchmarking types and benefits
• Introduction to SMRP framework and standards

Session 2 : SMRP Metrics Framework and Five Pillars

1. Business and Management - Cost control, budgeting, ROI metrics
2. Manufacturing Process Reliability - OEE, availability, uptime
3. Equipment Reliability - MTBF, MTTR, asset utilization
4. Organization and Leadership - Training, compliance, safety ​
5. Work Management - Planning, scheduling, work order efficiency

Session 3 : Key Reliability KPIs  

• Define and calculate MTBF, MTTR, MTTF
• Understand Availability calculations
• Master OEE and TEEP formulas and applications

·         Understand Preventive Maintenance Compliance (PMC)

• Learn Schedule Compliance calculations
• Analyze maintenance cost metrics
• Compare Preventive vs. Reactive maintenance ratios

Day 2: Benchmarking Methodology

Session 1 : Benchmarking Process and Methodology

Learning Objectives:

• Understand the types of benchmarking
• Learn the systematic benchmarking process (Plan-Do-Check-Act)
• Identify planning phase requirements and deliverables

Session 2 : Selecting and Defining Metrics for Benchmarking

• Identify critical KPIs aligned with business objectives
• Business relevance and impact
• Measurability and data availability
• Industry comparability
• Balance of leading and lagging indicators
• Establish performance baselines
• Set realistic targets based on industry standards ​

Session 3 : Data Collection and Quality Management

·         Understand data sources and collection methods

• Learn data accuracy and validation requirements
• Integrate CMMS systems for automated data collection
• Apply data quality frameworks

·         Practical Exercise: Create a data quality checklist for benchmarking programs

Day 3: Analysis & Interpretation

Session 1 : Leading vs Lagging Indicators

• Differentiate between leading and lagging indicators
• Develop balanced scorecard approach
• Understand indicator relationships and interdependencies

Leading Indicators (Predictive):

• PM Compliance
• Schedule Compliance
• Wrench Time
• Training Hours ​

Lagging Indicators (Historical):

• MTBF
• Equipment Availability
• Unplanned Downtime
• Total Maintenance Cost

Exercise: Classify reliability metrics as leading or lagging indicators

Session 2 : Benchmarking Analysis and Gap Identification

• Perform comparative analysis against benchmarks
• Identify and quantify performance gaps
• Calculate improvement opportunities and potential value

Analysis Techniques:

• Quartile analysis (Q1, Q2, Q3, Q4 performance)
• Best-in-class comparison
• Peer group analysis
• Trend analysis over time

Session 3: Industry Best Practices and World-Class Standards

• Review SMRP benchmark standards and targets
• Understand ISO 55001 asset management requirements
• Asset management policy
• Strategic asset management plan (SAMP)
• Performance monitoring and measurement
• Continuous improvement framework
• Learn industry-specific standards (oil & gas, manufacturing)
• Root Cause Analysis of Performance Gaps

Day 4: Dashboards & Reporting

Session 1: KPI Dashboard Design Principles

• Learn visualization best practices
• Understand dashboard layout principles
• Select appropriate metrics for different audiences (executive, operational, technical)

Design Principles:

• Use of visual hierarchy
• Color coding for status (red/yellow/green)
• Real-time data integration
• Mobile-responsive design
• Clear and concise metrics display ​

Dashboard Types:

• Executive dashboard (strategic KPIs)
• Operations dashboard (tactical metrics)
• Maintenance dashboard (detailed work metrics)

Session 2: Developing KPI Dashboards and Visualizations

• Create effective charts, graphs, and heat maps
• Design executive vs. operational dashboards
• Dashboard software tools (Power BI, Tableau, Excel)

·         Visualization Types:

·         Line charts for trends

·         Bar charts for comparisons

·         Heat maps for multiple variables

·         Gauges for target performance

·         Scorecards for KPI summary

Workshop: Create three different dashboard types using sample reliability data

Session 3 : KPI Reporting and Communication

• Develop effective reporting frameworks
• Communicate insights to stakeholders
• Create action-oriented reports that drive decisions

Day 5: Implementation & Improvement

Session 1 : Developing Reliability Improvement Action Plans

• Create SMART goals (Specific, Measurable, Achievable, Relevant, Time-bound)
• Prioritize improvement initiatives
• Impact on business objectives
• Implementation difficulty
• Resource availability
• Quick wins vs. long-term initiatives
• Develop detailed implementation roadmaps
• Action Plan Components

Session 2 : Implementing Benchmarking Programs

• Understand implementation challenges
• Resistance to change
• Data quality and availability
• Resource constraints
• Lack of standardized metrics
• Sustaining momentum
• Apply change management principles
• Engage stakeholders effectively

·         Establish monitoring systems

• Define review cycles (daily, weekly, monthly, quarterly)
• Apply continuous improvement frameworks (PDCA, Kaizen) ​

Session 3: Final Workshop - Develop Your Benchmarking Plan

• Apply all learned concepts

·         Review key concepts from all five days

• Complete final assessment & course feedback

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.

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