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Predictive Maintenance & Condition Monitoring

Calendar-based maintenance has a specific failure mode: it services equipment that did not need it and misses the machine that was about to fail. Condition monitoring replaces the calendar with evidence, but only where the failure develops slowly enough to be detected and the asset matters enough to justify the instrumentation. This day covers the techniques, how to read what they produce, and the assessment that decides which of your assets should be on a predictive programme at all.

Programme Agenda

Maintenance Strategies Compared

Run to failure, preventive, predictive and reliability-centred maintenance. Why run to failure is the correct choice for some assets, and the cost of applying predictive maintenance where it does not pay.

How Equipment Actually Fails

Failure patterns and the observation that most failures are not age-related, which undermines the assumption behind fixed-interval servicing. The P-F interval and what it means for inspection frequency.

Criticality Assessment

Ranking assets by consequence of failure, likelihood, and detectability. Deciding where to spend monitoring effort before buying any instrumentation.

Vibration Analysis

What vibration reveals about imbalance, misalignment, looseness and bearing degradation. Overall levels against spectral analysis, measurement points, and the trend that matters more than any single reading.

Thermography

Infrared inspection of electrical panels, connections, motors and mechanical drives. Emissivity, reflected temperature, load correction, and reporting a finding with the severity a manager can act on.

Oil Analysis and Ultrasound

Wear particles, contamination and lubricant degradation, and the sampling discipline that determines whether results mean anything. Ultrasound for leaks, electrical discharge and early bearing faults.

Motor Current Signature Analysis

Detecting rotor bar and stator faults from the current waveform without touching the machine. Where it complements vibration and where it is the only practical option.

Alarms, Trending and the Business Case

Setting thresholds that catch a real trend without generating noise, integrating results into the work order system, and building the investment case on avoided downtime, avoided secondary damage and deferred capital.

Learning Outcomes:
Select the right maintenance strategy for each asset class
Explain failure patterns and the P-F interval implications for inspection
Rank assets by criticality before committing to monitoring investment
Interpret vibration measurements for the common mechanical faults
Conduct and report a thermographic inspection with correct severity
Apply oil analysis and ultrasound with proper sampling discipline
Use motor current signature analysis where vibration is impractical
Set alarm thresholds and build the investment case on avoided cost

Duration: 1 Day (8 Hours)
Training Hours: 9:00 AM to 5:00 PM
Level: All levels
Training Mode: Physical, Online, or Hybrid
HRD Corp SBL-KHAS Claimable
Certificate of Completion included

Frequently Asked Questions

Maintenance and reliability engineers, plant and production managers, maintenance planners and technicians, and asset managers deciding on monitoring investment.

No. Vibration analyst certification follows a separate examined route with defined experience requirements. This programme covers all the techniques at the level needed to run a programme and interpret results, rather than qualifying a specialist in one.

Very. That is one of the most common situations we meet. The alarms, trending and work order integration module deals directly with it, and the criticality module often reveals that the sensors were installed on the wrong assets.

Where the venue allows, participants take vibration and thermal readings on demonstration equipment. For in-house delivery at a plant, readings are taken on your own assets, which usually surfaces something worth investigating.

Yes, this programme is HRD Corp SBL-KHAS claimable. Our team can assist your HR department with the documentation required for the grant application.

Yes. Any programme can be booked as a team day. Everyone works the same brief together, so your people come away having built something and knowing each other better.

If you are claiming under HRD Corp, the session has to fall at least 14 days after your HRD Corp approval. If you are not claiming, the date is flexible and we work around your calendar.

Put them on the self-paced e-learning instead. Your team works through the modules on our LMS in their own time, sits the assessment, and earns the same certificate, so nobody has to clear a full day together.

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