Practical Training for Preventive, Predictive & Reliability-Centered Maintenance
Practical corporate training covering maintenance fundamentals, preventive maintenance, predictive maintenance, condition monitoring, reliability engineering, failure analysis, maintenance planning, spare parts management, RCFA, FMEA/FMECA, RCM, MTBF, MTTR, availability, and maintenance performance improvement, with applications in industrial machinery, test benches, production equipment, and manufacturing systems.
Complete Syllabus
1. Maintenance Engineering Fundamentals
Maintenance Engineering Fundamentals; Maintenance Objectives; Equipment Reliability; Equipment Availability; Maintainability; Maintenance Strategies; Breakdown Maintenance; Corrective Maintenance; Preventive Maintenance; Predictive Maintenance; Condition-Based Maintenance; Proactive Maintenance; Maintenance KPIs.
2. Preventive Maintenance
Preventive Maintenance Fundamentals; Maintenance Intervals; Inspection Planning; Lubrication; Cleaning; Adjustment; Tightening; Component Replacement; Periodic Inspection; Maintenance Checklists; Preventive Maintenance Schedules; Equipment History; Maintenance Planning; PM Optimization.
3. Predictive Maintenance & Condition Monitoring
Predictive Maintenance Fundamentals; Condition Monitoring; Vibration Monitoring; Temperature Monitoring; Pressure Monitoring; Oil & Lubricant Monitoring; Electrical Measurements; Ultrasonic Inspection; Thermography Fundamentals; Trend Monitoring; Alarm Limits; Condition Assessment; Predictive Maintenance Planning.
4. Reliability Engineering for Maintenance
Reliability Fundamentals; Failure Rate; Hazard Rate; Bathtub Curve; MTBF; MTTF; MTTR; Availability; Maintainability; Reliability Improvement; Reliability-Centered Maintenance; Equipment Reliability; Failure Data Analysis; Reliability KPIs.
5. Failure Analysis & Root Cause Analysis
Failure Modes; Failure Mechanisms; Failure Analysis; 5 Why Analysis; Fishbone Analysis; Root Cause Analysis; Corrective Actions; Preventive Actions; Failure Investigation; Recurring Failures; Problem Solving; Failure Reporting; Reliability Improvement.
6. FMEA & FMECA
FMEA Fundamentals; FMEA Process; Failure Modes; Failure Causes; Failure Effects; Severity; Occurrence; Detection; Risk Priority; Risk Assessment; Criticality Analysis; FMECA; Corrective Actions; Maintenance FMEA; Equipment Risk Assessment.
7. Reliability-Centered Maintenance
RCM Fundamentals; Maintenance Strategy Selection; Functional Failure; Failure Consequences; Failure Management; Preventive Tasks; Predictive Tasks; Condition-Based Tasks; Scheduled Restoration; Scheduled Discard; Run-to-Failure; Maintenance Decision Logic; RCM Applications.
8. Maintenance Planning & Scheduling
Maintenance Planning; Maintenance Work Orders; Job Planning; Work Scope; Resource Planning; Manpower Planning; Tools & Equipment; Maintenance Scheduling; Shutdown Planning; Preventive Maintenance Scheduling; Backlog Management; Maintenance Prioritization; Maintenance Coordination; Work Completion.
9. Spare Parts & Maintenance Stores Management
Spare Parts Management; Critical Spares; Spare Parts Classification; Equipment Criticality; Minimum & Maximum Stock; Reorder Levels; Lead Time; Inventory Management; Spare Parts Availability; Obsolete Spares; Maintenance Stores; Spare Parts Planning; Cost Optimization.
10. Test Bench & Production Equipment Maintenance
Test Bench Maintenance; Measurement Equipment Maintenance; DAQ System Maintenance; Sensor Inspection; Calibration Management; Hydraulic System Maintenance; Pneumatic System Maintenance; Electrical Equipment; Motors & Drives; Control Systems; Automation Equipment; Production Machinery; Equipment Inspection; Maintenance Records.
11. Maintenance Performance & Data Analysis
Maintenance KPIs; MTBF; MTTR; Availability; OEE Fundamentals; Planned vs Breakdown Maintenance; Maintenance Cost; Equipment Downtime; Failure Trends; Maintenance Backlog; Pareto Analysis; Reliability Trends; Maintenance Dashboards; Performance Monitoring; Data-Driven Maintenance Decisions.
12. Practical Maintenance Engineering Applications
Industrial Machinery Maintenance; Production Equipment; Test Bench Maintenance; Rotating Equipment; Pumps; Motors; Compressors; Hydraulic Systems; Pneumatic Systems; Automation Systems; Preventive Maintenance Programs; Predictive Maintenance Programs; RCFA Case Studies; Maintenance Improvement Projects; Practical Engineering Applications.
Practical Calculations
MTBF | MTTR | Availability | Reliability | Failure Rate | Hazard Rate | Downtime | Maintenance Cost | OEE | Preventive Maintenance Interval | Equipment Utilization | Failure Frequency | Spare Parts Stock Level | Reorder Level | Maintenance Backlog | Mean Downtime
Practical Tools & Formats
Preventive Maintenance Checklist | Maintenance Schedule | Equipment History Sheet | Condition Monitoring Sheet | Failure Analysis Report | RCFA Template | FMEA | FMECA | RCM Decision Sheet | Maintenance Work Order | Spare Parts List | Equipment Criticality Matrix | Maintenance KPI Dashboard | Maintenance Report
Overall Training Flow
Equipment → Criticality Assessment → Maintenance Strategy → Preventive / Predictive Maintenance → Condition Monitoring → Failure Detection → Root Cause Analysis → Corrective Action → Reliability Improvement → Performance Monitoring
What Participants Will Learn
Participants will develop practical skills in preventive and predictive maintenance, condition monitoring, reliability analysis, failure investigation, RCFA, FMEA/FMECA, RCM, maintenance planning, spare parts management, maintenance KPIs and reliability improvement.
Training Methodology
Concepts → Worked Examples → Maintenance Calculations → Failure Analysis → Case Studies → Maintenance Planning → Data Analysis → Root Cause Analysis → Engineering Applications
Trainer Background
Manjunath Chunamur
Engineering professional with experience in Test & Validation, Reliability Engineering, Calibration, Measurement & Instrumentation, and Engineering Data Analysis, bringing practical industrial examples and application-focused learning.
Why Learn from Chunamur Labs?
- Practical maintenance engineering training
- Preventive and predictive maintenance
- Condition monitoring
- Reliability engineering
- MTBF, MTTR and availability calculations
- FMEA and FMECA
- Root Cause Failure Analysis
- Reliability-Centered Maintenance
- Maintenance planning and scheduling
- Spare parts management
- Test bench maintenance
- Maintenance KPI dashboards
- Practical engineering case studies
- Customized corporate training
Customized Corporate Training
Training can be customized based on your organization’s machines, production equipment, test benches, maintenance strategy, failure history, condition-monitoring requirements, spare parts requirements, reliability targets, and engineering objectives.