TRAINING COURSE: Certified Plant Maintenance Manager (CPMM)

 Predictive Maintenance

• Overview of predictive maintenance (PdM) concepts and benefits.
• Understanding the difference between Predictive and Preventive Maintenance.
• Techniques and tools used in PdM (Vibration analysis, Thermography, Ultrasound, etc.).
• Implementing PdM through condition monitoring and data analysis.
• Predictive maintenance technologies: IoT, AI, and machine learning.
• Role of sensors and real-time data in PdM.
• Developing a predictive maintenance strategy.
• Predictive maintenance metrics and KPIs.
• Case studies and examples of successful PdM implementation.

Inventory & Procurement

• The importance of effective inventory management in maintenance.
• Developing an optimal spare parts inventory system.
• Tools and techniques for inventory tracking and control (e.g., FIFO, Just-in-Time).
• Managing stock levels and minimizing excess inventory.
• Procurement processes for maintenance materials and equipment.
• Supplier selection, relationship management, and performance evaluation.
• Forecasting demand for spare parts and materials.
• Cost management in inventory procurement.
• Integrating inventory management with CMMS (Computerized Maintenance Management Systems).
• Inventory audits and performance analysis.

 Indoor Air Quality (IAQ)

• Importance of maintaining indoor air quality in facilities.
• Regulations and standards for indoor air quality (e.g., ASHRAE standards).
• Common IAQ problems in buildings (e.g., ventilation issues, mold, CO2 levels).
• IAQ monitoring tools and techniques.
• Strategies for improving and maintaining IAQ.
• Maintenance of HVAC systems for optimal IAQ.
• Air filtration and air exchange systems.
• The role of IAQ in employee health, productivity, and safety.
• Identifying and addressing sources of indoor air pollution.
• Best practices for indoor air quality management.

 Total Productive Maintenance (TPM)

• Introduction to Total Productive Maintenance and its principles.
• The 8 Pillars of TPM: Autonomous maintenance, planned maintenance, focused improvement, and more.
• TPM implementation process and steps.
• Role of operators and maintenance teams in TPM.
• How to engage employees in TPM for increased productivity.
• Measuring success through TPM metrics.
• Preventing equipment breakdowns and maximizing efficiency.
• Relationship between TPM and Lean Manufacturing.
• Continuous improvement in TPM practices.
• Case studies of TPM implementation and results.

• The importance of maintenance training for team effectiveness.
• Designing effective training programs for maintenance personnel.
• Training needs analysis: Identifying gaps in skills and knowledge.
• Building a strong work culture focused on safety, quality, and reliability.
• Encouraging collaboration and teamwork among maintenance staff.
• Continuous learning and development opportunities.
• Creating a positive work environment that fosters innovation and performance.
• Implementing mentorship and knowledge transfer systems.
• The impact of work culture on maintenance performance and outcomes.

• Understanding preventive maintenance and its role in minimizing unplanned downtime.
• Developing and implementing a PM strategy.
• Preventive maintenance vs. Corrective maintenance: Advantages and limitations.
• Scheduling and frequency of PM tasks.
• Risk-based maintenance and prioritization of assets for PM.
• PM checklists and documentation.
• Tracking and measuring the effectiveness of PM programs.
• Using CMMS to manage and optimize PM activities.
• Addressing challenges in maintaining a robust PM system.
• Continuous improvement and feedback loops in PM.

Health & Safety in Maintenance

• Introduction to health and safety regulations (OSHA, ISO, etc.) in maintenance.
• Risk assessment and hazard analysis for maintenance activities.
• Personal protective equipment (PPE) and its proper use in maintenance tasks.
• Safe work practices and procedures.
• Safety management systems and safety audits.
• Emergency response planning and procedures.
• Ergonomics in maintenance tasks and reducing physical strain.
• Ensuring compliance with environmental and safety laws.
• Safety training and awareness programs for maintenance personnel.
• Incident reporting and accident investigations.

Reliability-Centered Maintenance (RCM)

• Overview of Reliability-Centered Maintenance and its principles.
• Understanding the RCM decision process (what, how, and why to maintain).
• Identifying critical assets and failure modes.
• Determining the most appropriate maintenance strategy for each asset.
• Combining RCM with other maintenance approaches (e.g., TPM, PdM).
• The role of RCM in improving asset reliability and operational efficiency.
• RCM methodology: Functional analysis, failure modes, effects, and criticality analysis.
• How to implement RCM in your organization.
• RCM metrics and tracking.
• Case studies: Successful RCM implementation in various industries.

Maintenance Planning & Scheduling

• The importance of effective planning and scheduling in maintenance.
• Developing a maintenance work plan and schedule.
• Work order management and prioritization techniques.
• Resources management: Manpower, tools, and materials.
• Strategies for minimizing downtime and improving equipment availability.
• Short-term vs. long-term maintenance planning.
• Performance metrics for planning and scheduling.
• Balancing preventive maintenance with unplanned corrective maintenance.
• The role of CMMS in maintenance scheduling.
• Best practices for optimizing maintenance workflows.

Documentation in Maintenance

• The role of documentation in maintenance management.
• Types of maintenance documents: Work orders, logs, reports, checklists, and manuals.
• Best practices for creating, storing, and accessing maintenance documents.
• The importance of maintaining accurate records for compliance and audits.
• Document control systems and software solutions.
• Using documentation to analyze past failures and prevent future issues.
• Safety and regulatory documentation in maintenance operations.
• Ensuring transparency and accountability through proper documentation.
• Training staff on the importance and use of documentation.