Reliability Academy

Flagship in-person workshop

Maintenance & Reliability Best Practices Workshop

A 5-day workshop delivered at site by Erik Hupjé personally. Your team goes through the full Road to Reliability Framework to create a roadmap they own when Erik leaves. Includes 6 months of implementation support.

Outcomes

What your team will learn to do

The Maintenance & Reliability Best Practices Workshop applies the full Road to Reliability™ Framework to your operating site. Over 5 days on-site, Erik takes your maintenance and reliability leaders through the practices that high-performing sites use to deliver durable improvement.

These are the high-impact best practices the workshop is built around:

  • Increase maintenance workforce capacity by ~35% without hiring

    Through better planning & scheduling and waste elimination during execution.

  • Eliminate the 40–60% of PM tasks that add little or no value

    Identify low-value preventive maintenance tasks, optimise the PM program, reduce workload, cut cost, and increase uptime.

  • Build a Defect Elimination process that fixes the 80% of failures that are repeat issues, for good

    Tackle the 80% of failures that are repeat issues, including both bad actors and minor defects.

  • Build the leadership behaviours and culture that sustain the technical work

    Use a practical leadership and culture model to initiate change, then keep the technical improvements alive once the initial push is over.

No death by PowerPoint

Engaging discussions, case studies, and exercises drawn from real scenarios across client sites worldwide. This is not an academic course or exam prep. Your team analyses your plant’s performance, finds the gaps, and builds the roadmap on Day 5.

Curriculum

Workshop content: 5 topics over 5 days

The workshop runs for 5 days at your site, with up to 25 participants (optimum 12–16 for engagement). We cover roughly one topic per day, with flex for discussion and applied exercises on your equipment and your data.

01

Topic 1: Framework for Reliability Improvement & Cost Reduction

Sets the scene. Industry promotes complex frameworks; the "Best of the Best" achieve world-class performance (98%+ uptime) by focusing relentlessly on a few fundamentals.

  • "Best of the Best" study (benchmarked hundreds of sites worldwide)
  • Framework overview
  • Lean concepts in Maintenance & Reliability
02

Topic 2: Planning & Scheduling to Increase Productivity

Most maintenance organisations lose time waiting for permits, isolations, parts, tools, and other trades. Effective Planning & Scheduling cuts this waste, but only when the full end-to-end process works in practice.

  • The productivity challenge and how waste occurs during maintenance
  • Measuring productivity / wrench time
  • How Planning & Scheduling eliminates waste
  • Prioritisation using quality standards and a Corrective Maintenance Prioritisation Tool (CMPT) based on RIME / RAM methodology
  • Planning maintenance work: planning principles, planning frameworks, work packs, and use of BOMs
  • Managing backlog: Plannable / Planned / Ready-for-Execution backlog states
  • Scheduling: Frozen Weekly Schedule, Long-Term Schedule, Maintenance Schedule vs Integrated Activity Schedule
  • Execution & Closeout: As Found / As Left, Failure Codes, and use of M3s
  • Continuous Improvement
03

Topic 3: Optimising PM Programs using RCM / PMO / FMEA

Many PM programs are unoptimised. Teams do too much maintenance, often too much intrusive maintenance, and reliability gets worse rather than better.

  • History & Development of RCM: Nowlan & Heap plus Waddington
  • Principles of Effective PM Programs
  • Different types of Maintenance: TBM / CBM / PdM / FFM / RBM and when to use them
  • CBM and the P-F curve
  • Equipment criticality: risk-based vs consequence-based, SCE/PCE update
  • Optimisation methodologies: RCM / PMO / FMEA / RBI / RBM
  • Importance of Work Instructions
  • How to effectively document your PM program
  • Adopting a Living Program approach
04

Topic 4: Effective RCA & Defect Elimination

80% of failures that occur in industrial plants have occurred before. Most organisations focus on getting better at fixing repeat failures instead of eliminating them.

  • Importance of eliminating repeat failures ("Best of the Best" research)
  • RCA vs DE
  • Bad Actors vs Minor Defects
  • Origin of defects
  • Integrated process for managing Bad Actors and Defects
  • DE vs Management of Change
  • Causal Learning Concepts & Learning Organisation
  • Common Mind Traps
05

Topic 5: Leadership & Culture

Technical improvements only deliver lasting results when supported by the right leadership behaviours and a reliability-focused culture. This topic gives leaders practical tools they can use without large budgets or waiting for senior leadership.

  • Why culture is the make-or-break factor for sustained reliability improvement, including parallels with the evolution of safety culture
  • 4-element culture model: what we say / reward / accept / do
  • Leadership impact formula: what leaders say counts 1×, what they model counts 2×, and what they reward counts 3×
  • Reliability Culture Ladder: 5 levels (toxic, reactive, effective, proactive, enlightened), adapted from Hudson
  • Recognition schemes: best work request, best job plan, best 5-Why
  • Reliability behaviours in performance appraisals and visible leadership presence in scheduling and review meetings
  • Just Culture model and the reliability equivalent of non-negotiable "life-saving rules"

The support doesn’t end on Day 5

Most courses end on Day 5. This one keeps helping for six more months.

  • Six live monthly Q&A sessions with Erik in the six months after the workshop.
  • The Q&A sessions are built around helping your team execute the roadmap and resolve any implementation challenges that surface in the first six months, not generic content.

Optional add-ons (on request)

We can adjust the scope of the core topics or add specialised content based on your priorities. Two add-ons we run on request:

  • Benchmarking and sustainable cost reduction using Zero-Based Budgeting and Activity-Based Cost Models
  • Developing and using Maintenance & Reliability metrics: leading and lagging indicators, visualisation, what to measure, relevant international standards

Pricing

What it costs

$25,000 + travel costs

For up to 25 participants. That covers the 5 days on site, all templates and toolkits, and the six monthly Q&A sessions afterwards.

Included

What’s included

  • 5-day intensive workshop at your plant or office
  • Workshop delivered by Erik Hupjé personally, not by an associate
  • 6 months of monthly live Q&A sessions with Erik after the workshop
  • Group size up to 25 participants (optimum 12–16 for engagement)
  • Practical exercises based on your plant, performance, and implementation priorities
Erik Hupjé

Delivered personally by

Erik Hupjé

My passion is for continuous improvement and keeping things simple. Through the Reliability Academy, I help Maintenance & Reliability professionals around the globe – people like yourself – improve their plant’s reliability and their organisation’s bottom line.

I am a Certified Maintenance & Reliability Practitioner (CMRP), Certified Reliability Leader (CRL), Certified Asset Management Assessor (CAMA) and a Chartered Professional Engineer (CPEng).

But those are just credentials, it is my industry experience and practical approach to the topics I teach that our students and clients appreciate the most.

Choosing a workshop

Which workshop is right for you?

We run two in-person workshops. This one covers the full Road to Reliability™ Framework across all four elements; the other goes deep on planning & scheduling alone. Which one fits depends on whether you are setting a site-wide direction or fixing how work gets planned day to day.

MRBPThis page

Maintenance & Reliability Best Practices Workshop

The whole framework in five days. For leadership and reliability teams building a site-wide roadmap across all four elements.

MPS

Maintenance Planning & Scheduling Workshop

Planning & scheduling, end to end. For the planners, schedulers, supervisors, and managers who run work management daily.

View workshop

Proof

We delivered this workshop five times over two years for one of the largest oil & gas operators in Kazakhstan

Five deliveries of this workshop for the same client over two years. They kept coming back. Feedback below is from the two most recent sessions (45 participants) and is representative of all five.

9.4

/10

Course overall

9.4

/10

Course content

9.8

/10

Course instructor

9.3

/10

Course materials

4.8

/5

Would recommend to a colleague

43 of 45 participants (96%) answered 4–5.

It gave me a clear and structured approach to improving reliability.
Workshop participant, oil & gas operator, Kazakhstan
All the info is easy to correlate with our current situation in the company, so it makes it easy to think about further improvement.
Workshop participant, oil & gas operator, Kazakhstan
Everything was superb. We are glad to have you as instructor.
Workshop participant, oil & gas operator, Kazakhstan

FAQs

MRBP workshop FAQs

Up to 25 participants. We find the workshop runs best with 12 to 16: small enough that every participant gets airtime in discussions and exercises, large enough to bring a real cross-section of disciplines (planners, schedulers, supervisors, reliability engineers, operations) into the room.

Yes. The 5-topic structure is fixed, but the examples, exercises, and the Day 5 roadmap are built around your equipment, your KPIs, and the issues you are actually trying to solve. We agree the customisation scope during the call.

Six live monthly Q&A sessions with Erik directly after the workshop. The sessions are built around helping your team execute the roadmap and resolve the implementation challenges that surface in the first 6 months. Most workshops end on Day 5. This one keeps helping for 6 more months.

Oil & gas, mining, chemicals, large-scale manufacturing, and major logistics operations (ports, airports). The content is industry-agnostic at the framework level but the examples and exercises lean heavily on asset-intensive, safety-critical environments.

Possibly. We have run condensed versions of MRBP with smaller leadership teams. We make those calls case-by-case during the call. Usually we end up recommending one of the online courses (PS100/PM100) for the wider team plus a short on-site leadership intensive.

Erik delivers the workshop in English. If you need delivery in another language, raise it on the call and we will discuss what is feasible.

The workshop is $25,000 plus travel costs, for up to 25 participants. That covers the 5 days on site, all templates and toolkits, and the six monthly Q&A sessions afterwards.

MRBP covers the same content as PS100, PM100, DE100, and LC100, applied directly to your site. Teams who attend MRBP often enrol the wider workforce in the corresponding online courses afterwards. The online courses reinforce what the leadership team learned in person and extend the same vocabulary across the site.

Yes. The Reliability Sprints (our coaching engagements for Planning & Scheduling, PM optimisation, and Defect Elimination) pair naturally with MRBP. The workshop builds the framework and the roadmap; the sprints help you execute against specific elements of the roadmap. Raise it on the call.

P.S. MRBP is the most direct way to bring the Road to Reliability™ framework into your site. Erik delivers it personally, your leadership team builds the roadmap with him in the room, and the 6 months of follow-up keep the support going through the hardest part: early implementation. Book a call when you are ready to see whether it fits.