Preventative maintenance

4 days

course code 3. 16

What is the course for


Developing a preventative and improved maintenance system


Reducing maintenance costs 


Increasing plant availability

All companies that decide to invest in equipment of any type want to maximise its use while reducing management and maintenance costs. In particular, companies want to have the machine available when the market requires the product, and not be constrained by unforeseen interruptions.

The implementation of a preventive maintenance system reduces total maintenance costs and increases equipment efficiencies thanks to the increased equipment availability through introducing targeted inspections, replacements and repairs. All this can be achieved only through professional development for the people in the maintenance department. This training course provides the elements to design and implement such a change in the maintenance department.


  • Develop a preventive and improved maintenance system
  • Reduce maintenance costs
  • Increase equipment availability
  • Develop and enhance people’s skills

Addressed to

  • Plant managers
  • Maintenance managers
  • Production managers
  • Maintenance technicians
  • Production supervisors
  • Process engineers


Preliminary activities

  • How to identify the training that a team requires.
  • How to identify the boundaries for experimentation within a project.
  • How to select the team’s resources.
  • The logic needed to define a master plan for implementing preventive maintenance.
  • Key performance indicators (KPIs) for preventative maintenance and their connection with production efficiency indicators.
  • The Lock Out Tag Out procedure for maintenance and production technicians.
  • Safety maps: creation and use.

Defining starting points for machines and processes

  • Learning the importance of having machine lists and their respective bill of materials up to date.
  • The ABC classification of machines and production lines
  • The ABCZ classification of spare parts
  • Creating the KPI Maintenance Database
  • Mapping the maintenance process to search for waste and opportunities

Restoring machinery and equipment to its basic condition and eliminating any flaws

  • How to identify, tackle, and troubleshoot machine anomalies
  • Applying problem solving techniques to technical interruptions
  • Applying 5S to technical workshops, learning its benefits
  • How to create a “fail-safe” standardised lubrication system.
  • How to create a system for mapping maintenance skills for a “skills matrix” and its related training plans.

Creating a system for managing maintenance

  • Recording and extending problem solving activities
  • Defining strategies for the logging maintenance carried out
  • Defining how to report maintenance costs
  • How to improve spare parts management
  • How to create a maintenance audit system
  • How to create a maintenance budget
  • Initiating the maintenance meeting system

Preventive and predictive maintenance

  • Different maintenance policies
  • Maintenance inspections and standard maintenance procedures
  • How to create a preventive maintenance plan
  • How to create a predictive maintenance plan
  • How to manage maintenance plans
  • Extending and improving maintenance plans with FMECA and RCM
  • The “zero base budget” technique for maintenance

You will experience

  • How to use ABC and ABCZ flow charts
  • How to develop a VSM in a maintenance area
  • How to apply a fault analysis form in a real scenario
  • How to map maintenance skills and develop a skills matrix
  • How to create a “visual” lubrication standard
  • How to create a maintenance meeting system with related agendas
  • How to use the ABCX Matrix for warehouse analysis.

Download the in-company training catalogue