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ICTD International Centre for Training and Development

Maintenance Auditing, Benchmarking & Performance Improvement Towards World-Class Status

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About the course

This highly participative program introduces candidates to the auditor’s role, how to prepare, undertake and report an audit as well as some of the one to one interview skills necessary to the role. The program includes guidance on identifying Best Practice and gaps against current practice (using benchmarking as appropriate) and through example and exercises how an audit report might highlight and recommend Performance Improvement. General Performance Improvement drivers, tools and techniques, in line with Lean Six Sigma practices are discussed and demonstrated, including specific maintenance performance measures, key performance indicators and objective setting.

Participants will be assisted in developing the following competencies:

  • An understanding of the purpose of auditing and the role of the auditor
  • The ability to scope, prepare, undertake and report an audit review
  • An appreciation of international maintenance organization models and standards
  • Experience in audit interviewing techniques
  • The ability to prepare a case for improvement initiatives
  • An appreciation of a range of Lean Six Sigma tools and techniques

This program covers all the essential skills necessary to understand how an effective and efficient maintenance function is implemented, supported and improved. This includes the use and application of a model maintenance management audit methodology consistent with the recognized maintenance excellence framework to assess the current state of maintenance and identify opportunities for improvement. Similarly, participants will learn how benchmarking and a range of Lean 6S tools can be adapted to the needs of maintenance.

Course Objectives

The objectives of this program are to provide participants with an awareness and working knowledge of how to:

  • Audit their maintenance operations
  • Use the results to establish and monitor an effective improvement strategy
  • Establish auditing as a key element of their maintenance management strategy
  • Make a business case for improvement initiatives
  • Use reference benchmarking and a range of Lean Six Sigma tools and techniques to drive improvement initiatives

Course Outline

Day 1

Introduction and Foundation Concepts

  • Introduction to Auditing
  • Introduction to Benchmarking
  • Maintenance Management models for different operations
  • International standards models
  • Performance Measures

Day 2

Maintenance Auditing

  • The Maintenance Auditing Process
  • Maintenance Auditing Methodology
  • Conducting a Maintenance Audit
  • Maintenance Audit Simulation Case Study

Day 3

Maintenance Auditing and Benchmarking

  • Maintenance Audit Simulation Case Study
  • Using Maintenance Audit Results to Plan Improvement Strategies
  • The Maintenance Benchmarking Process
  • Maintenance Benchmarking Methodology
  • Benchmarking Tools and Techniques

Day 4

Maintenance Benchmarking and Performance Measurement

  • Maintenance Performance Measures and Metrics
  • Key Performance Indicators
  • Integrating Benchmarking resulting into improvement and objective setting processes
  • Integrating Maintenance Auditing and Benchmarking into the Performance Measurement System to establish improvement objectives and strategies

Day 5

Auditing, Benchmarking and Maintenance Improvement

  • Case study
  • Identifying Improvement Opportunities
  • Making the Business Case
  • Standards and Lean 6S
  • Program Review and conclusion

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course addresses the needs of a diverse audience of maintenance professionals with an interest in maintenance management and maintenance improvement and the application of leading edge techniques such as maintenance auditing, benchmarking and lean 6S. The course is beneficial to general managers who have oversight responsibility for maintenance management and maintenance organizational units, operations engineering and maintenance managers with direct line responsibility as well as staff support responsibility for maintenance, maintenance supervisors, maintenance engineers and maintenance planners and schedulers and to those with responsibility for standards and/or continuous improvement.

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