Preventive Maintenance Manager Course

Lesson 1 • Defining Preventive Maintenance

Covers PM definition, scope, and distinction from reactive and predictive strategies. Anchors all subsequent chapters in shared vocabulary.

Lesson 2 • Roles and Responsibilities in PM

Maps stakeholder roles from technicians to executives in a PM programme. Clarifies accountability structures students will manage.

Lesson 3 • Types of PM Tasks and Intervals

Classifies time-based, usage-based, and condition-based PM tasks. Provides the task taxonomy used throughout the course.

Lesson 4 • Introduction to Maintenance Metrics

Introduces MTBF, MTTR, PM compliance rate, and availability as foundational KPIs. Sets measurement baseline for later performance chapters.

Lesson 1 • Creating a Comprehensive Asset Register

Covers data fields, naming conventions, and hierarchy for asset records. A complete register is the prerequisite for all PM planning activities.

Lesson 2 • Failure Mode Identification

Introduces FMEA principles to identify how assets fail and what PM tasks prevent each mode. Links failure modes directly to task selection.

Lesson 3 • Criticality Assessment Methods

Teaches risk matrix, weighted scoring, and failure consequence analysis for ranking assets. Criticality scores drive PM frequency and resource decisions.

Lesson 1 • Establishing Task Frequencies

Uses OEM recommendations, failure history, and criticality scores to set defensible intervals. Frequency decisions directly affect PM programme effectiveness.

Lesson 2 • Safety and Lockout/Tagout Integration

Embeds energy isolation, PPE requirements, and hazard warnings into PM task documents. Safety integration is mandatory before any field deployment.

Lesson 3 • Writing Effective PM Procedures

Covers step-by-step instruction writing, action verb usage, and acceptance criteria. Well-written procedures reduce errors and training time.

Lesson 4 • Document Control and Version Management

Establishes revision control, approval workflows, and archiving for PM documents. Prevents use of outdated procedures in the field.

Lesson 1 • Scheduling Principles and Constraints

Covers production windows, shutdown opportunities, and labour capacity as scheduling inputs. Understanding constraints prevents schedule overload and missed PMs.

Lesson 2 • Annual and Weekly PM Planning

Translates task frequencies into annual calendars and weekly work packages. Balanced loading prevents backlog buildup and technician overload.

Lesson 3 • Managing PM Deferrals and Backlog

Establishes deferral approval criteria, risk documentation, and backlog reduction strategies. Uncontrolled deferrals erode PM programme integrity.

Lesson 4 • Spare Parts and Materials Planning

Aligns parts procurement with PM schedules to ensure material availability at task time. Parts shortages are a leading cause of PM deferrals.

Lesson 1 • Data Quality and Master Data Management

Covers data standards, duplicate prevention, and audit processes for CMMS records. Poor data quality undermines scheduling accuracy and performance reporting.

Lesson 2 • Configuring PM Triggers and Auto-Generation

Sets up time, meter, and event-based triggers to auto-generate PM work orders. Automation reduces manual scheduling effort and missed task generation.

Lesson 3 • CMMS Reporting and KPI Dashboards

Builds standard PM performance reports and real-time dashboards from CMMS data. Reports drive the management decisions covered in later chapters.

Lesson 4 • Mobile Work Order Execution

Enables technicians to receive, execute, and close PM work orders via mobile devices. Mobile execution improves data capture speed and accuracy.

Lesson 1 • PM Task Effectiveness Review

Evaluates whether individual PM tasks are preventing failures or consuming resources without benefit. Ineffective tasks are revised or eliminated.

Lesson 2 • Key Performance Indicators for PM

Defines PM compliance, wrench time, schedule attainment, and cost per PM as primary KPIs. KPI selection determines what behaviours the programme reinforces.

Lesson 3 • Continuous Improvement Cycles

Applies Plan-Do-Check-Act cycles to sustain PM programme improvement over time. Structured cycles prevent regression after initial programme gains.

Lesson 4 • Interval Optimisation Techniques

Uses failure history, condition data, and reliability models to refine PM intervals. Optimised intervals reduce cost whilst maintaining or improving reliability.

Lesson 1 • Establishing Condition Baselines

Defines healthy-state baselines and alert thresholds for monitored parameters. Baselines are required before any condition trend can be interpreted.

Lesson 2 • Condition Monitoring Technology Overview

Surveys vibration analysis, thermography, oil analysis, and ultrasound as primary CM tools. Technology selection depends on failure mode and asset criticality.

Lesson 3 • Integrating CM Data into the CMMS

Routes condition monitoring alerts to CMMS work order generation and asset history. Integration closes the loop between monitoring and maintenance action.

Lesson 4 • Building a Reliability-Centred Maintenance Bridge

Positions PM and CM within an RCM framework to align task selection with failure consequences. RCM thinking elevates PM from routine to strategic.

Lesson 1 • Cross-Functional Collaboration

Coordinates PM programme needs with operations, engineering, procurement, and finance teams. Effective collaboration prevents scheduling conflicts and resource gaps.

Lesson 2 • Developing a PM Programme Strategy

Aligns PM programme goals with organisational reliability, safety, and cost objectives. A documented strategy provides direction and justifies resource requests.

Lesson 3 • Budget Development and Justification

Builds PM budgets using labour, parts, contractor, and technology cost components. Justification requires linking spend to reliability and risk reduction outcomes.

Lesson 4 • Benchmarking and Industry Best Practices

Compares PM programme metrics against industry benchmarks to identify performance gaps. External benchmarking validates internal targets and inspires improvement.

Lesson 5 • Change Management for PM Implementation

Applies structured change management to overcome resistance and sustain PM adoption. Cultural change is the most common barrier to PM programme success.