Intro to Asset Integrity and Maintenance

This 3 day course is designed to apply common sense to asset integrity and maintenance. We directly relate maintenance activity to increased production, and asset integrity to safety allowing everybody to understand the benefits.

If there was ever an area where complexity is unnecessarily created it is maintenance. On the one hand we have maintenance personnel who fiercely defend their budget and can be guilty of exaggerating risk as a result. On the other hand we have leadership that really struggles to get clear answers to what seem like simple questions.

Both parties really want the same outcome and so they need a less complicated explanation of what should be going on.

Target Audience

This course is aimed at maintenance and operations personnel, from technician to management and leadership. Good performance is cultural as well as technical. Only by involving all members of a team in pursuit of a common goal will progress be achieved. This course seeks to establish new norms for everyone from the newest hires to the most senior leaders.

Course Topics

The overall aim of the course is to understand the maintenance and asset integrity cycle.

Breakdown maintenance was the original form of maintenance and despite advances in maintenance theory if you get it wrong you still end up with breakdown maintenance. We discuss the complication of maintenance over the years, identifying what is value adding, what is merely complicating matters and what is critical.

Pre planned maintenance of process plant is now the norm in industry, but with the advent of condition monitoring, expert systems, reliability centred maintenance, Kaizen and total productive maintenance, no one can afford to be ignorant of the application of the latest approaches. Understanding the different options is essential to maximize the benefits of investment in maintenance.

Having established the correct blend of options we then need to programme workflow using today’s computerised maintenance management systems (CMMS). The maintenance process needs to be practically blended with the day to day requirements of operation.

We then move on to consider the data needed from each activity to allow us to measure the effectiveness of the maintenance activity and how that data is used to adjust activity accordingly.

Course Overview

Most companies consider maintenance as an expense or at worst a necessary evil. This course directly relates maintenance activity to increased production, allowing management to understand the business case and benefits, operations to understand why they should release the equipment and maintenance to be able to do their job effectively.

Most importantly attendees will be able to quantify the return on carrying out a maintenance activity. this will prove whether the activity is worthwhile or not.

They will become familiar with the reliability toolkit, too many companies present Reliability Centred Maintenance (RCM) and their like as the answer to all the world’s ills when in fact no one tool is suitable for all purposes. There are many maintenance reliability tools in the kit.

We’ll review the toolkit and by understanding the right tools, for the right job and the commercial benefits of that job, maintenance activity can be optimised.

Learning Objectives

At the end of the course delegates will be able to compare the different approaches to maintenance, RCM and TPM, understand their place in the maintenance toolbox and select appropriate applications for each approach.

You will learn:

  • Criticality analysis
  • How to measure lost opportunity, what you could have produced
  • ‘Bad actor’ analysis including a comparison of different reliability techniques
  • Computerised maintenance management and reliability data
  • How to incorporate improvement with day to day maintenance
  • Understand the difference between breakdown maintenance, pre planned maintenance and on condition maintenance
  • Be familiar with reliability analysis techniques
  • Appreciate how computer based systems can be used to aid maintenance
  • Understand the importance of data collection and measurement of production losses


Howard Thomas has advocated practical approaches to handling complexity for over 20 years. He has a unique ability to make the complex clear for his clients and audiences.
He combines an in depth technical background with a wide ranging business experience but is probably best known for his engaging style of presentation.

He is formally technically accredited as a Fellow of Engineers Australia and a Chartered Professional Chemical Engineer and has worked on hydrocarbon installations all over the world, from roles as a technician to executive consultancy.