Maintenance Training

Lesson 1 • Safety Fundamentals for Technicians

Covers hazard identification, personal protective equipment, and lockout/tagout principles. Safety compliance underpins every hands-on task in this course.

Lesson 2 • Types of Maintenance Strategies

Contrasts reactive, preventive, predictive, and reliability-centered approaches. Provides the framework for selecting the right strategy per asset type.

Lesson 3 • Maintenance Roles and Responsibilities

Defines the technician's duties within a maintenance organisation. Connects individual accountability to overall equipment reliability and team performance.

Lesson 4 • Maintenance Documentation Basics

Introduces work orders, equipment history logs, and standard forms. Accurate records enable trend analysis and regulatory compliance throughout the course.

Lesson 1 • Workshop Organisation and Housekeeping

Applies 5S methodology to tool storage, work area layout, and waste management. An organised workspace reduces errors and supports efficient maintenance flow.

Lesson 2 • Power Tools and Pneumatic Equipment

Addresses drills, grinders, impact wrenches, and air-powered tools. Safe operation and maintenance of power tools are linked to workshop hazard control.

Lesson 3 • Precision Measuring Instruments

Teaches use of calipers, micrometers, dial indicators, and feeler gauges. Measurement accuracy directly affects component fit and equipment performance.

Lesson 4 • Lifting and Material Handling Safety

Covers manual lifting techniques, hoists, slings, and rigging fundamentals. Safe material handling prevents musculoskeletal injuries and equipment drops.

Lesson 1 • Maintenance KPI Review and Improvement

Analyses OEE, schedule compliance, and cost per unit to drive continuous improvement. KPI review closes the loop between maintenance execution and strategic goals.

Lesson 2 • Work Order Planning and Scheduling

Covers job scoping, parts kitting, labour estimation, and schedule coordination with operations. Effective planning reduces wrench time loss and repeat work orders.

Lesson 3 • Failure Mode and Effects Analysis

Guides FMEA development to rank failure modes by severity, occurrence, and detectability. FMEA outputs prioritise maintenance tasks and design improvements.

Lesson 4 • Root Cause Analysis Methods

Applies 5-Why, fishbone, and fault tree analysis to identify failure root causes. RCA findings drive corrective actions that eliminate repeat failures.

Lesson 1 • Ultrasound and Acoustic Inspection

Applies ultrasonic detectors to find air leaks, bearing defects, and electrical discharge. Ultrasound complements vibration analysis for comprehensive condition monitoring.

Lesson 2 • Developing PM Task Lists

Builds equipment-specific PM tasks from manufacturer data, failure history, and criticality. Well-designed task lists are the foundation of a proactive maintenance programme.

Lesson 3 • PM Schedule Optimisation

Uses failure data and condition monitoring results to adjust PM frequencies and task scope. Optimisation reduces maintenance cost while maintaining equipment reliability targets.

Lesson 4 • Thermography and Infrared Inspection

Covers infrared camera operation, emissivity settings, and thermal anomaly identification. Thermography detects electrical hot spots and mechanical friction before failure.

Lesson 1 • Lubricant Types and Properties

Distinguishes oils, greases, and solid lubricants by viscosity, base stock, and additive package. Correct lubricant selection prevents wear and reduces energy consumption.

Lesson 2 • Lubrication Programme Development

Guides creation of a lubrication route, task list, and interval schedule for a facility. A structured programme reduces unplanned failures and lubricant waste.

Lesson 3 • Contamination Control

Addresses ingress prevention, filtration ratings, and storage practices for lubricants. Contamination is the primary cause of premature bearing and gear failure.

Lesson 4 • Oil Analysis and Condition Monitoring

Teaches sampling, laboratory analysis interpretation, and trending of oil condition data. Oil analysis detects internal wear before catastrophic failure occurs.

Lesson 1 • Bearings: Inspection and Replacement

Identifies bearing types, failure modes, and correct installation methods. Bearing health directly impacts rotating equipment reliability and service life.

Lesson 2 • Gearbox Inspection and Servicing

Teaches oil sampling, seal replacement, and gear wear assessment for enclosed gearboxes. Gearbox condition directly affects downstream equipment performance.

Lesson 3 • Shafts, Couplings, and Alignment

Covers shaft inspection, coupling types, and precision alignment procedures. Misalignment is a leading cause of premature bearing and seal failure.

Lesson 4 • Fasteners, Seals, and Gaskets

Covers bolt grades, torque sequences, O-ring selection, and gasket installation. Proper fastener and sealing practice prevents leaks and structural failures.

Lesson 1 • Fluid Power Fault Diagnosis

Applies pressure gauges, flow meters, and circuit tracing to locate hydraulic and pneumatic faults. Structured diagnosis minimises system downtime and fluid waste.

Lesson 2 • Fluid Power Principles

Introduces pressure, flow, and force relationships in hydraulic and pneumatic systems. These principles underpin every diagnostic and repair task in this chapter.

Lesson 3 • Hydraulic Fluid Management

Teaches fluid sampling, contamination control, and fluid change procedures. Fluid cleanliness is the single largest factor in hydraulic component life.

Lesson 4 • Pneumatic Circuit Maintenance

Addresses compressors, FRL units, actuators, and solenoid valves in pneumatic systems. Proper maintenance ensures consistent actuator speed and force output.

Lesson 1 • Control Panels and Switchgear

Addresses inspection, cleaning, and component replacement in control panels and switchgear. Panel integrity ensures reliable power distribution and control system function.

Lesson 2 • Reading Electrical Schematics

Teaches interpretation of single-line diagrams, ladder logic, and wiring diagrams. Schematic reading is essential for accurate fault diagnosis and repair.

Lesson 3 • Motor Inspection and Testing

Covers insulation resistance, winding continuity, and bearing condition checks for motors. Motor testing prevents unexpected failures and extends service intervals.

Lesson 4 • Electrical Safety and Isolation

Establishes safe work on electrical systems through isolation, testing, and permit procedures. Electrical safety is the prerequisite for all tasks in this chapter.