Breakdown Root Cause Analysis & Maintenance Management
Cut downtime by managing breakdowns systematically. Participants set maintenance policies and KPIs, classify equipment by criticality, analyse failures with 5 Why, 4M and FMECA, and build maintenance and spare-parts systems that prevent recurrence.
At a glance
- 3 days
Who it's for
- Maintenance managers, engineers & supervisors
- Reliability engineers
- Production supervisors
Learning objectives
- Set maintenance vision, policies and KPIs (MTBF, MTTR, downtime)
- Classify equipment by criticality (ABC)
- Analyse breakdowns with 5 Why, 4M and FMECA
- Build a maintenance management and spare- parts system
- Control maintenance cost and share knowledge with one-point lessons
Detailed content
- Maintenance vision & mission
- Maintenance policies
- Maintenance KPIs: MTBF, MTTR, downtime, availability
- Equipment ABC/criticality classification
- 5 Why & 4M (fishbone) analysis
- Building a maintenance management system
- Spare parts management system design
- Breakdown deployment & analysis
- FMECA
- One-Point Lessons (OPL)
- Breakdown management process
- Maintenance cost
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Maintenance Foundations
- Root Cause & Systems
- Breakdown Management
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Calculate OEE and the six big losses from a real machine log
- Failure analysis of a recent breakdown (5-Why, fishbone, FMEA)
- Build a preventive / autonomous maintenance plan for one asset
- Solve a real problem with 8D or A3 from containment to verification
Tools and templates you keep
- OEE calculator (Excel)
- PM schedule and CIL (clean–inspect–lubricate) sheet
- Breakdown analysis report template
- 8D report and A3 templates
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- JIPM TPM pillars
- SMRP Body of Knowledge
- ISO 55000 (asset management)
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Maintenance, Engineering & Reliability · Practitioner
Frequently asked questions
How long is Breakdown Root Cause Analysis & Maintenance Management?
The program runs 3 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
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Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.