Module 1. The Maintenance and Reliability Function in 2026

• Why reliability matters: cost of downtime, safety, quality and delivery impact
• Maintenance, reliability and asset management: how they fit together
• The evolution of maintenance: reactive, preventive, predictive, prescriptive
• Maintenance organisation models and key roles
• The Indian and global industrial landscape: sectors, employers, skill gaps
• Maintenance maturity models and self-assessment
• Lab: Maturity assessment of a case plant

Module 2. Asset Management Strategy and Business Alignment

• Asset management principles and the 2024 ISO 55000 family
• Strategic asset management plan and objectives
• Asset hierarchy, functional locations and the asset register
• Life cycle management, life cycle cost and total cost of ownership
• Repair, refurbish or replace decisions; capital renewal planning
• Risk management and business continuity in asset-intensive operations
• Building the business case for reliability
• Lab: One-page strategic asset management plan

Module 3. How Equipment Fails

• Failure, failure mode, mechanism, cause, effect and consequence
• Common mechanisms: wear, fatigue, corrosion, erosion, overload, contamination, electrical
• The six failure patterns and why the bathtub curve misleads
• The P-F curve and P-F interval
• Hidden vs evident failures; maintenance-induced and human-error failures
• Lab: Failure mode library for a pump-motor set

Module 4. Reliability Statistics and Life Data (Weibull) Analysis

• Core metrics: reliability, failure rate, MTBF, MTTF, MTTR and availability types
• Distributions in practice: exponential, Weibull, normal, lognormal
• Preparing failure data; censored and suspended data
• Weibull analysis: interpreting shape and scale, mixed failure modes
• Repairable systems and reliability growth tracking
• Using results for PM intervals, spares and warranty decisions
• Lab: Weibull analysis of bearing failure data

Module 5. System Reliability Modelling and RAM Analysis

• Reliability block diagrams: series, parallel, k-out-of-n, standby
• Redundancy decisions and common-cause failures
• Reliability allocation and the limits of handbook predictions
• Monte Carlo simulation and RAM studies for projects and debottlenecking
• Lab: RAM model of a utility system

Module 6. Designing and Buying for Reliability and Maintainability

• Reliability in capital projects: specifications and design reviews
• Design for maintainability: access, standardisation, testability
• Equipment selection, vendor evaluation and parts standardisation
• Understanding vendor reliability tests for procurement decisions
• Installation, commissioning, operational readiness and early equipment management
• Lab: Reliability and maintainability specification checklist

Module 7. Asset Criticality Analysis, FMEA and FMECA

• Criticality analysis methods and risk matrices
• Consequence categories: safety, environment, production, cost, reputation
• Equipment and process FMEA step by step; risk priority vs action priority
• FMECA and criticality ranking
• Turning FMEA outputs into maintenance tasks
• Lab: Criticality ranking and FMECA for a production line

Module 8. Reliability-Centred Maintenance and PM Optimisation

• RCM logic: functions, functional failures, failure modes, consequences
• Task selection: condition-based, time-based, failure-finding, run-to-failure, redesign
• Streamlined RCM for existing plants
• PM optimisation: rationalising legacy PM programmes
• Lab: RCM analysis of a critical asset

Module 9. Preventive and Condition-Based Maintenance

• Designing effective PM tasks, intervals and job instructions
• Vibration analysis, infrared thermography and ultrasound
• Oil and wear-debris analysis; motor current analysis
• NDT for static equipment
• Route-based vs online monitoring; setting alarm limits
• Lab: Building a condition-monitoring programme

Module 10. Precision Maintenance and Defect Elimination

• Lubrication excellence: storage, contamination control, lube routes
• Shaft alignment, balancing, bearing installation, bolting and torque
• Maintenance quality and craft standards
• Defect elimination programmes
• Lab: Lubrication audit checklist

Module 11. Total Productive Maintenance and Lean Maintenance

• TPM pillars; autonomous maintenance and operator inspection rounds
• Planned maintenance within TPM
• OEE, six big losses and production loss accounting
• Lean in maintenance: waste, 5S, visual management, kaizen
• Process reliability and variation reduction
• Lab: OEE and loss-tree analysis
• Part D — Maintenance Execution

Module 12. Work Management: Identification, Planning and Scheduling

• The work order lifecycle and work request quality
• Prioritisation systems and backlog management
• Job plans, estimating, kitting and staging
• Weekly and daily scheduling, wrench time and schedule compliance
• Coordination between operations and maintenance
• Lab: Building a weekly schedule from a backlog

Module 13. Shutdowns, Turnarounds and Outages

• Shutdown strategy and intervals
• Scope challenge and freeze, planning timeline, readiness reviews
• Critical path planning and contractor mobilisation
• Execution control, safety and quality during shutdowns
• Start-up and post-shutdown review
• Lab: Shutdown scope and readiness plan

Module 14. MRO Spares and Materials Management

• Spares classification and criticality
• Stocking policies: min-max, insurance spares, consignment
• Storeroom practice, preservation of stored spares, kitting
• Obsolescence, repairables and vendor management
• Inventory KPIs and working-capital trade-offs
• Lab: Stocking decision for critical spares

Module 15. Maintenance Safety and Regulatory Compliance

• LOTO, permit-to-work, confined space, hot work, work at height
• Management of change, process safety and risk-based inspection
• Safety instrumented systems and functional safety basics
• India’s regulatory framework
• Global frameworks: ISO 45001 and environmental compliance
• Legal liability, documentation and professional ethics
• Lab: Compliance register for a case plant

Module 16. Maintenance Data, CMMS/EAM and Data Quality

• Data types and sources; failure coding and taxonomy
• CMMS/EAM functions, selection and implementation
• Mobile maintenance and digital work instructions
• Data governance and fixing poor data
• Lab: Failure-code structure and data-quality audit

Module 17. Root Cause Analysis and Failure Investigation

• When to trigger RCA; preserving evidence
• 5 Whys, cause-and-effect diagrams, logic trees, fault tree analysis
• Failure analysis of physical parts
• FRACAS: closing the loop on corrective actions
• Verifying effectiveness and sharing lessons learned
• Lab: Full RCA on a repeat failure

Module 18. Maintenance KPIs, Benchmarking and Budgeting

• Leading vs lagging indicators; a balanced KPI framework
• Dashboards and performance reviews
• Internal and external benchmarking
• Maintenance budgeting, cost control and cost-per-unit metrics
• Lab: KPI dashboard and annual budget

Module 19. Industry 4.0 and AI in Maintenance

• IIoT sensors, edge computing and connectivity
• Machine-learning anomaly detection and remaining-useful-life prediction
• Prescriptive maintenance and digital twins
• Generative AI assistants for technicians and planners
• AR remote support; drones and robots for inspection
• OT cybersecurity
• Running pilots that scale: readiness, data, ROI
• Lab: Predictive maintenance pilot plan

Module 20. Sustainability, Energy and ESG in Maintenance

• Maintenance as an energy lever: compressed air, motors, steam, pumps
• Emissions, leaks and environmental performance
• India’s carbon market, energy efficiency schemes and BRSR reporting
• Life extension, refurbishment and circularity
• Lab: Energy-loss walk-through and savings estimate

Module 21. Reliability Leadership, Culture and Workforce

• Building a reliability culture; leading change
• Partnership between operations and maintenance
• Contractor and AMC management
• Skills matrices, multi-skilling and competency development
• Knowledge capture and succession in an ageing workforce
• Lab: 12-month reliability improvement roadmap

Module 22. Capstone and Career Toolkit

• Integrated case: reliability transformation of a fictional Indian plant
• Career paths and role-based competency maps
• Portfolio, CV and interview preparation

Apply for the certification

https://www.vskills.in/certification/certified-maintenance-and-reliability-professional