Introduction

Efficient maintenance planning, scheduling, and cost control are essential for ensuring asset reliability, optimizing equipment uptime, and minimizing operational costs. Poorly managed maintenance leads to unscheduled downtime, cost overruns, and safety hazards. This 12-day intensive training program, developed by Global Horizon Training Center, provides maintenance professionals with the strategies, tools, and techniques to effectively plan, schedule, and control maintenance activities, while optimizing resources and ensuring budget discipline.

Objectives

By the end of the training program, participants will be able to:

• Understand and implement best practices in maintenance planning and scheduling.

• Develop effective preventive, predictive, and corrective maintenance programs.

• Apply modern tools and software for maintenance scheduling.

• Monitor and control maintenance costs using KPIs and financial metrics.

• Integrate maintenance management with budgeting and performance tracking.

• Enhance communication and coordination between operations and maintenance teams.

Target Audience

• Maintenance planners and supervisors

• Maintenance engineers and technicians

• Reliability and asset management professionals

• Maintenance cost controllers and analysts

• Operations and plant managers

• Anyone involved in maintenance execution and budgeting

Organizational Impact

Organizations will benefit by:

• Increased asset reliability and reduced downtime

• Optimized labor, materials, and spare parts usage

• Better budget forecasting and cost accountability

• Improved preventive and predictive maintenance implementation

• Stronger cross-functional collaboration between departments

Training Outline

Day 1: Foundations of Maintenance Management

• Objectives and types of maintenance (reactive, preventive, predictive)

• Role of planning and scheduling in maintenance excellence

• Maintenance maturity models and lifecycle management

• Key performance indicators (KPIs) and benchmarking

Day 2: Maintenance Planning Principles

• Responsibilities of planners vs. supervisors

• Maintenance work identification and work request process

• Job scoping, priority setting, and resource estimation

• Standard job plans and planning libraries

Day 3: Work Order Management

• Work order lifecycle and tracking

• Creating accurate and complete work orders

• Job packaging and material requisitioning

• Coordination with stores and procurement

Day 4: Maintenance Scheduling Techniques

• Weekly and daily scheduling processes

• Loading labor and resource levelling

• Use of Gantt charts and backlog management

• Scheduling optimization strategies

Day 5: Preventive and Predictive Maintenance Scheduling

• Developing PM programs based on OEM and RCM

• Condition monitoring and predictive tools

• Lubrication and inspection scheduling

• Planning shut-downs and turnaround maintenance

Day 6: Computerized Maintenance Management Systems (CMMS)

• Overview of CMMS functionalities and benefits

• Data quality and hierarchy structure

• Planning and scheduling in CMMS (SAP PM, Maximo, etc.)

• Reports, KPIs, and data-driven decisions

Day 7: Cost Control and Budgeting in Maintenance

• Types of maintenance costs (labor, material, contract, capital)

• Maintenance budgeting process

• Forecasting and variance analysis

• Controlling overtime, spare parts, and vendor costs

Day 8: Maintenance Cost Tracking and Analysis

• Cost coding and work order cost assignment

• Tracking internal vs. outsourced maintenance

• Cost per asset and cost per failure metrics

• ROI of maintenance interventions

Day 9: Reliability-Centered Maintenance (RCM) Integration

• RCM overview and asset criticality analysis

• Integrating planning and scheduling with RCM findings

• FMEA and failure pattern identification

• Reliability improvement action plans

Day 10: Shutdown, Turnaround and Outage Planning (STO)

• Phases of shutdown planning

• Task list preparation and critical path scheduling

• Resource planning and risk management

• Cost control and lessons learned documentation

Day 11: Maintenance Performance and Continuous Improvement

• Maintenance KPIs and reporting dashboards

• Root cause analysis of planning failures

• Audit checklists for planning and scheduling

• Implementing continuous improvement and LEAN tools

Day 12: Workshop and Practical Assignment

• Develop a complete maintenance plan and schedule

• Create a maintenance budget and cost tracking sheet

• Group presentations and peer review

• Final wrap-up, Q&A