After completing the course, participants will be able to:-

improve maintenance planning, increase CMMS effectiveness, monitor maintenance KPIs, control maintenance cost, prepare realistic budgets, and generate meaningful performance reports. The course will support OQ Oman teams in improving asset reliability, maintenance efficiency, cost visibility, and management decision-making.

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

• Understand the principles and functions of effective maintenance management in industrial facilities.
• Differentiate between corrective, preventive, predictive, condition-based, and reliability-centered maintenance strategies.
• Use CMMS effectively for work order control, asset history, planning, scheduling, and reporting.
• Develop structured maintenance plans and schedules aligned with operational requirements.
• Identify and apply key maintenance KPIs for measuring performance and improving reliability.
• Analyze maintenance backlog, schedule compliance, PM compliance, downtime, MTBF, MTTR, and availability.
• Prepare maintenance budgets based on manpower, materials, spare parts, contracts, services, and shutdown activities.
• Track and control maintenance costs using proper cost coding, variance analysis, and reporting tools.
• Convert CMMS data into clear maintenance performance reports for supervisors and management.
• Develop improvement actions to optimize maintenance performance, reduce cost, and enhance asset reliability.

• Interactive instructor-led presentations covering key maintenance management and CMMS concepts.
• Practical examples from oil, gas, petrochemical, utilities, and process industries.
• Hands-on exercises on planning, KPIs, backlog, budgeting, cost control, and reporting.
• Group discussions to share challenges, lessons learned, and improvement opportunities.
• Case studies on maintenance failures, CMMS data quality, budget issues, and KPI gaps.
• Workshops on dashboards, reports, and performance improvement action plans.
• Daily review exercises to reinforce learning and workplace application.

Day 1: Fundamentals of Maintenance Management and Asset Performance

Session 1: Introduction to Maintenance Management

• Definition and purpose of maintenance management
• Maintenance role in safety, reliability, availability, and production continuity
• Maintenance as a business function, not only a technical activity
• Relationship between maintenance, operations, engineering, procurement, and finance
• Maintenance challenges in oil, gas, petrochemical, and process industries

Session 2: Maintenance Strategies

• Corrective maintenance
• Preventive maintenance
• Predictive maintenance
• Condition-based maintenance
• Reliability-centered maintenance
• Risk-based maintenance
• Run-to-failure strategy and when it is acceptable
• Selecting the right maintenance strategy for different asset types

Session 3: Maintenance Management Process

• Asset register and asset hierarchy
• Equipment criticality classification
• Maintenance job identification
• Work request and work order workflow
• Planning, scheduling, execution, feedback, and close-out
• Maintenance history and continuous improvement

Session 4: Practical Exercise

• Developing a basic asset hierarchy
• Classifying equipment criticality
• Selecting suitable maintenance strategies for sample plant equipment

Day 2: CMMS Utilization and Work Management

Session 1: CMMS Fundamentals

• Purpose and benefits of CMMS
• CMMS as a maintenance decision-support tool
• Main CMMS modules
• Asset master data
• Work order management
• Preventive maintenance module
• Spare parts and inventory link
• Maintenance history and reporting

Session 2: Work Order Management

• Work request creation
• Screening and approval
• Priority classification
• Job planning
• Material reservation
• Manpower allocation
• Scheduling
• Execution feedback
• Technical completion and close-out

Session 3: CMMS Data Quality

•  Importance of accurate maintenance data
•  Common CMMS data problems
•  Incomplete work order feedback
•  Wrong failure codes
•  Poor equipment history
•  Duplicate assets and wrong asset coding
•  Data governance and user discipline

Session 4: Practical Workshop

•  Sample work order flow from request to close-out
•  Developing work order priority criteria
•  Reviewing examples of poor and good work order feedback
•  Identifying CMMS data quality improvement actions

Day 3: Maintenance Planning, Scheduling, Backlog and KPI Management

Session 1: Maintenance Planning Principles

•  Difference between planning and scheduling
•  Role of the maintenance planner
•  Job scope development
•  Estimating manpower, tools, materials, and duration
•  Standard job plans
•  Job packages
•  Maintenance coordination with operations

Session 2: Maintenance Scheduling

•  Weekly maintenance schedule
•  Daily schedule
•  Frozen schedule concept
•  Resource leveling
•  Coordination meetings
•  Schedule compliance
•  Causes of schedule break-in and poor execution

Session 3: Maintenance Backlog Management

•  Definition of maintenance backlog
•  Ready backlog vs total backlog
•  Emergency, urgent, routine, and deferred work
•  Backlog aging
•  Backlog prioritization
•  Backlog reduction strategy

Session 4: Maintenance KPIs

•  Purpose of KPIs
•  Leading and lagging indicators
•  Availability
•  Reliability
•  MTBF
•  MTTR
•  PM compliance
•  Schedule compliance
•  Corrective maintenance percentage
•  Emergency work percentage
•  Backlog size and backlog aging
•  Maintenance cost indicators

Session 5: Practical KPI Exercise

•  Calculating MTBF and MTTR
•  Measuring schedule compliance
•  Analyzing backlog reports
•  Interpreting KPI trends and identifying improvement acti

Day 4: Maintenance Budgeting, Cost Planning and Cost Control

Session 1: Maintenance Budgeting Fundamentals

•  Purpose of maintenance budgeting
•  Annual maintenance budget cycle
•  Budget ownership and accountability
•  Link between maintenance plan and maintenance budget
•  Budgeting for routine maintenance, shutdowns, contracts, spare parts, manpower, and services

Session 2: Maintenance Cost Classification

•  Labor cost
•  Material cost
•  Spare parts cost
•  Contractor cost
•  Equipment rental cost
•  Shutdown and turnaround cost
•  Emergency maintenance cost
•  Capital vs operating maintenance cost

Session 3: Maintenance Cost Control

•  Cost coding and cost centers
•  Work order cost tracking
•  Planned vs actual cost
•  Budget variance analysis
•  Cost overrun causes
•  Maintenance cost per asset
•  Maintenance cost as percentage of asset replacement value
•  Cost reduction without compromising reliability or safety

Session 4: Budget and Cost Reporting

•  Monthly maintenance cost report
•  Budget utilization report
•  Forecasting maintenance expenditure
•  Variance explanation
•  Corrective action planning
•  Reporting cost performance to management

Session 5: Practical Workshop

•  Preparing a sample maintenance budget
•  Analyzing planned vs actual maintenance cost
•  Preparing a simple variance report
•  Identifying cost optimization opportunities.

Day 5: Maintenance Reporting, Dashboard Development and Improvement Planning

Session 1: Maintenance Reports

•  Purpose of maintenance reporting
•  Types of reports: daily, weekly, monthly, quarterly, and annual
•  Reports for supervisors, managers, and senior management
•  Technical reports vs management reports
•  Key elements of effective maintenance reports

Session 2: KPI Dashboard Development

•  Selecting meaningful KPIs
•  Avoiding too many KPIs
•  KPI target setting
•  Trend analysis
•  Traffic light reporting
•  Dashboard structure
•  Maintenance performance summary

Session 3: CMMS-Based Reporting

•  Extracting useful data from CMMS
•  Work order status reports
•  PM compliance reports
•  Backlog reports
•  Cost reports
•  Failure history reports
•  Equipment reliability reports
•  Data interpretation and decision-making

Session 4: Maintenance Improvement Planning

•  Identifying performance gaps
•  Root cause analysis of poor maintenance performance
•  Developing action plans
•  Assigning responsibilities
•  Setting target dates
•  Monitoring improvement progress
•  Continuous improvement cycle

Session 5: Final Group Exercise and Course Wrap-Up

•  Prepare a maintenance performance report using sample data
•  Present KPI results and cost findings
•  Recommend improvement actions
•  Group discussion and feedback
•  Key learning summary
•  Final Q&A session

BTS attendance certificate upon completing 80% of the program

Request Info

Salutation MR Miss ENG DR

Full Name*

Designation

Company*

Country * Egypt Saudi Arabia Ireland UAE France Turkey Bahrain South Africa Nigeria Oman Nethersland United Kingdom Malaysia Kuwait Online Indonesia Qatar Morocco Jordan Switzerland Singapore Spain Italy Uganda

City * Cairo Mansoura Ireland Abu Dhabi Riyadh Dubai Istanbul Manama Abuja Paris Kuala-Lumpur Amsterdam Muscat Salalah Jeddah Dammam Cape Town London Kuwait Online Indonesia Doha Casablanca Marrakesh Singapore Geneva Zürich Amman Barcelona Rome Marbella Milan Uganda Scotland Madrid Jakarta Manchester

Email*

Enquiry*

Captcha*

Enter Captcha*

Submit