Introduction

In today's competitive landscape, effective maintenance planning and scheduling are no longer just administrative tasks—they are critical to maximizing operational efficiency, ensuring asset reliability, and controlling costs. Organizations are shifting away from reactive, "fix-it-when-it-breaks" models to proactive, data-driven strategies that prevent failures before they occur. This requires a systematic approach to work management, from initial request to final completion, ensuring every resource is used optimally and every task is executed at the right time.

This comprehensive training course is designed to equip professionals with the methodologies and practical skills needed to transform maintenance operations. Participants will learn how to design robust planning processes, leverage modern CMMS software to streamline workflows, and develop achievable schedules that enhance technician productivity and minimize downtime. The curriculum covers key areas such as work order management, resource allocation, backlog management, and performance measurement, empowering individuals to become leaders in driving organizational reliability and profitability.

Duration: 

10 days

Target Audience:

• Maintenance planners and schedulers
• Maintenance supervisors and managers
• Reliability engineers
• Operations and plant managers
• CMMS administrators
• Technicians transitioning to a planning role
• Supply chain and procurement personnel
• Asset managers
• Project managers
• Continuous improvement specialists

Objectives:

• Master the roles and responsibilities of a maintenance planner versus a scheduler.
• Develop a structured process for managing the maintenance work order lifecycle.
• Implement a robust system for work prioritization based on asset criticality and risk.
• Optimize resource allocation and labor capacity for maximum efficiency.
• Learn to use CMMS software to streamline planning and scheduling activities.
• Measure and analyze key performance indicators (KPIs) to drive improvement.
• Create effective job plans that reduce wrench time and improve technician productivity.
• Develop strategies for managing and reducing the maintenance backlog.
• Understand the link between proactive maintenance and asset reliability.
• Apply communication and coordination techniques to align maintenance with operations.

Module 1: Foundations of Maintenance Management

• The shift from reactive to proactive maintenance
• Defining the goals of a world-class maintenance organization
• The five pillars of maintenance excellence
• Understanding the total cost of ownership
• The importance of reliability and its impact on the business

Module 2: The Planning and Scheduling Process

• The maintenance work order lifecycle
• The distinct roles of a planner and a scheduler
• The purpose and benefits of maintenance planning
• Common planning and scheduling challenges and solutions
• Integrating planning with other departments (e.g., operations, procurement)

Module 3: Work Order Management

• Creating a clear and detailed work request
• The work order as the central document
• Standardizing work order information
• The role of a Computerized Maintenance Management System (CMMS)
• Using a CMMS for work order tracking and historical data

Module 4: Work Prioritization and Backlog Management

• Developing a robust work prioritization system
• Ranking work orders based on safety, risk, and asset criticality
• Defining and managing the maintenance backlog
• Strategies for backlog reduction and control
• The importance of a clean and up-to-date backlog

Module 5: Developing Effective Job Plans

• The components of a complete and accurate job plan
• Estimating labor hours and material requirements
• Including safety procedures and permits
• Providing clear step-by-step instructions for technicians
• Using job templates for repeatable tasks

Module 6: CMMS and EAM Fundamentals

• Introduction to CMMS and Enterprise Asset Management (EAM) systems
• Key features of modern maintenance software
• Navigating work order modules and asset registries
• Using the CMMS for parts and inventory management
• Generating reports and dashboards from CMMS data

Module 7: Resource Management and Leveling

• Identifying the resources needed for a job (labor, tools, equipment)
• Assessing technician skill sets and availability
• The process of resource leveling to balance workload
• Managing contractor and external resources
• The impact of resource allocation on schedule adherence

Module 8: The Scheduling Process

• The difference between a plan and a schedule
• Scheduling principles for optimal execution
• Creating a rolling, weekly maintenance schedule
• Coordinating with operations for equipment downtime
• Handling unplanned and emergency work orders

Module 9: Materials and Inventory Management

• The link between planning and parts availability
• Staging parts and tools for upcoming jobs
• Inventory control and optimization strategies
• Preventing stockouts of critical spares
• Using the CMMS for inventory tracking and reordering

Module 10: Shutdown, Turnaround, and Outage Planning

• The unique challenges of major projects
• Developing a detailed shutdown plan and schedule
• Critical path management for complex tasks
• Pre-shutdown planning and post-shutdown review
• Managing cross-functional teams during an outage

Module 11: Key Performance Indicators (KPIs)

• Why measure maintenance performance
• Defining and selecting relevant maintenance KPIs
• Calculating and interpreting KPIs like MTBF and MTTR
• Using metrics to identify improvement opportunities
• Creating a scorecard to track performance over time

Module 12: Continuous Improvement

• The role of feedback from technicians
• Conducting root cause analysis (RCA)
• The importance of a culture of continuous improvement
• Using historical data to refine plans and schedules
• Implementing a corrective action plan

Module 13: Integrating Maintenance with Operations

• Establishing clear communication channels
• Collaborative planning for production and maintenance activities
• Managing conflicts and competing priorities
• The role of the maintenance manager as a business partner
• Gaining buy-in from all stakeholders

Module 14: Predictive and Preventive Maintenance

• The difference between planned and unplanned maintenance
• Designing an effective preventive maintenance (PM) program
• Using condition monitoring and predictive technologies
• Scheduling PMs based on time, usage, or condition
• The benefits of a proactive approach to asset health

Module 15: Auditing and Optimizing the Process

• Conducting a maintenance planning and scheduling audit
• Identifying bottlenecks and inefficiencies in the workflow
• Refining data collection and analysis
• Setting performance benchmarks for the team
• Developing a strategy for ongoing optimization

Module 16: Technology and the Future of Maintenance

• Leveraging mobile technology for maintenance tasks
• The role of IoT sensors and connected assets
• Using data analytics and AI for predictive insights
• The future of CMMS and EAM systems
• Staying current with industry trends and best practices

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 7 working days before commencement of the training.