Mastering Maintenance Audit

Course Introduction

This 5-day training program focuses on the essential knowledge and skills required to conduct effective maintenance audits. Participants will learn how to assess maintenance systems, processes, and performance to ensure compliance with industry standards, improve reliability, and enhance efficiency. This course covers audit methodologies, tools, and techniques, as well as how to identify areas for improvement and implement best practices to optimize maintenance management within various industries.

Objectives

By the end of this course, participants will be able to:

•     Understand the principles and objectives of a maintenance audit.
•     Implement a structured approach to audit planning, preparation, and execution.
•     Analyze maintenance management systems, including personnel, processes, and performance metrics.
•     Identify gaps, inefficiencies, and areas of improvement within the maintenance program.
•     Evaluate compliance with relevant standards, regulations, and best practices.
•     Develop action plans and recommendations for improving maintenance practices and ensuring long-term sustainability.

Target Audience

•     Maintenance Managers and Supervisors
•     Reliability Engineers and Technicians
•     Operations and Facilities Managers
•     Internal and External Auditors in the manufacturing, oil & gas, energy, and chemical industries
•     Anyone involved in maintenance management, audit, or continuous improvement

Daily Topics

Day 1: Introduction to Maintenance Audits

    What is a maintenance audit? Definition, objectives, and scope

    Key concepts: Maintenance management, reliability-centered maintenance, and total productive maintenance

    Types of maintenance audits: Operational audits, compliance audits, process audits, and asset management audits

    The role of the auditor: Skills, ethics, and responsibilities

    The importance of maintenance audits in improving performance and reducing costs

    Industry standards and regulations related to maintenance audits (ISO 55000, ISO 9001, etc.)

Workshop: Case study analysis: Review a sample maintenance audit report and identify key findings

Day 2: Maintenance Audit Planning and Preparation

    Key components of a successful maintenance audit plan

    Establishing audit objectives and defining the scope of the audit

    Identifying audit criteria: Compliance, effectiveness, efficiency, and safety

    Selecting audit methods and tools: Checklists, surveys, and interviews

    Preparing an audit team and defining roles and responsibilities

    Scheduling and preparing for the audit: Documentation review and stakeholder engagement

Practical Exercise:Develop an audit plan for a given maintenance management system

Day 3: Conducting the Maintenance Audit

    Audit execution: How to collect data, conduct interviews, and observe maintenance activities

    Reviewing maintenance records: Work orders, maintenance logs, and performance data

    Evaluating maintenance processes: Planning, scheduling, execution, and follow-up

    Assessing the condition of critical assets and equipment

    Identifying areas of non-compliance or inefficiency and documenting findings

    Engaging with staff and management to understand challenges and root causes

Hands-On Exercise: Conduct a simulated maintenance audit on a selected system and prepare audit findings

Day 4: Analyzing Audit Findings and Identifying Gaps

    Analyzing collected data: How to identify trends, inefficiencies, and weaknesses

    Assessing maintenance performance metrics: MTTR (Mean Time to Repair), MTBF (Mean Time Between Failures), and availability

    Identifying gaps in training, resources, and processes

    Benchmarking against industry standards and best practices

    Root cause analysis: Methods such as the 5 Whys and Fishbone Diagram to uncover underlying issues

    Prioritizing findings and classifying them into actionable categories

Workshop: Group activity: Analyze a set of audit findings and categorize them based on impact (e.g., critical, high priority, low priority)

Day 5: Reporting and Implementing Recommendations

    Audit reporting: How to present audit findings and recommendations clearly and concisely

    Developing a corrective action plan: Identifying corrective, preventive, and improvement actions

    Communicating audit results to management and stakeholders

    Creating actionable recommendations: Cost-effective solutions for improvement

    Ensuring follow-up and monitoring to track the progress of corrective actions

    Leveraging audit results for continuous improvement and strategic planning

Final Project: Prepare and present an audit report with findings, recommendations, and action plans for improvement in a maintenance management system

Assessment:

•     Daily quizzes and knowledge checks
•     Practical exercises and group activities
•     Final presentation of audit findings and recommendations

Certification:

Upon successful completion of the course, participants will receive a Certificate in Mastering Maintenance Audits.

For registration & more information please contact

NAYEL Training Centre 

Tel: +971 4 379 7245 | Mob: +971 50 249 6876 | WhatsApp: +971 50 249 6876

Email:  [email protected]