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Courses/Industrial and Process Eng./Industrial and Process Eng. - General

The Cost of Waiting: Building Reliability Before Equipment Fails

Transform your maintenance strategy from reactive to proactive to prevent costly downtime, maximize asset lifespan, and protect your bottom line from unexpected failures.

Created byNathan Catherall
BeginnerUpdated Aug 3, 2026
The Cost of Waiting: Building Reliability Before Equipment Fails

What You'll Learn

check_circleUnderstand why equipment failures rarely occur as isolated events and how proactive maintenance improves reliability.
check_circleApply reliability-centred maintenance principles to reduce recurring failures and optimise asset performance.
check_circleEvaluate maintenance planning, shutdown strategies and asset criticality to improve operational outcomes.
check_circleUse root cause analysis and continuous improvement techniques to build a more reliable maintenance culture.

About This Course

Many industrial facilities invest heavily in maintenance activities, yet unplanned downtime, recurring failures, and production disruptions continue to impact safety, productivity, and profitability. While equipment failures are often treated as isolated events, the underlying causes frequently develop months or even years before the failure occurs. The challenge for maintenance and engineering teams is not simply repairing assets quickly, but identifying and addressing the conditions that lead to failure in the first place.

As industries face increasing pressure to improve reliability, optimise maintenance expenditure, and maximise asset performance, organisations are shifting from reactive maintenance models towards data-driven, reliability-focused strategies. Success requires more than implementing maintenance plans; it demands a deeper understanding of asset behaviour, failure mechanisms, maintenance systems, workforce capability, and operational decision-making.

This session explores how engineers can improve reliability outcomes through proactive maintenance strategies, effective shutdown planning, root cause analysis, and continuous improvement practices.

Key Topics Discussed:

  • Reactive versus proactive maintenance strategies
  • Reliability-centred maintenance (RCM) principles
  • Failure modes and root cause analysis
  • Predictive and condition-based maintenance
  • Preventive maintenance optimisation
  • Maintenance planning and scheduling
  • Shutdown and turnaround management
  • Asset criticality and risk-based maintenance
  • CMMS and SAP maintenance systems
  • Reliability culture and workforce engagement
  • Continuous improvement in maintenance operations
  • Lessons from manufacturing and process industries

Your Instructor

Nathan Catherall
Nathan Catherall

Chartered Mechanical Engineer

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Nathan Catherall, CEng, is a Chartered Mechanical Engineer with expertise in mechanical maintenance, asset reliability, and industrial engineering. He has experience delivering maintenance strategies, equipment reliability improvements, and continuous improvement initiatives within large-scale manufacturing environments. He holds an MSc in Mechanical Manufacturing Engineering and is committed to applying engineering best practices to improve plant performance, safety, and operational efficiency.

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