Asset Maintenance Course

Lesson 1 • The Purpose of Maintenance

Explains why maintenance exists as a business function and its impact on safety, reliability, and cost. Links maintenance outcomes to organisational performance.

Lesson 2 • Maintenance Stakeholders and Roles

Maps the people involved in maintenance decisions, from operators to executives. Clarifies accountability and communication pathways.

Lesson 3 • Key Maintenance Terminology

Introduces standard industry terms used across maintenance disciplines. Ensures consistent communication throughout the course.

Lesson 4 • Regulatory and Standards Context

Surveys the regulatory environment and industry standards that govern maintenance practice. Prepares students to recognise compliance obligations.

Lesson 1 • Selecting the Right Strategy

Provides a decision framework for matching maintenance strategies to asset criticality and context. Synthesises all strategies covered in the chapter.

Lesson 2 • Preventive Maintenance Principles

Covers time-based and usage-based maintenance scheduling. Students design basic PM task lists and intervals for common assets.

Lesson 3 • Predictive Maintenance Overview

Introduces condition-monitoring techniques that trigger maintenance based on asset health data. Connects data collection to decision-making.

Lesson 4 • Reliability-Centred Maintenance Concepts

Presents RCM logic for selecting maintenance tasks based on failure consequences. Builds analytical thinking for strategy selection.

Lesson 1 • Understanding Failure Modes

Classifies mechanical, electrical, and process failure modes. Provides the analytical foundation for all root cause methods.

Lesson 2 • Preventing Failure Recurrence

Translates root cause findings into PM task changes, design modifications, and operator training. Closes the loop from analysis to prevention.

Lesson 3 • Root Cause Analysis Techniques

Teaches the five-why method, fishbone diagrams, and fault tree analysis. Students apply each technique to structured case studies.

Lesson 4 • Failure Reporting and Documentation

Covers how to document findings in a format that supports corrective action and knowledge retention. Links analysis output to maintenance planning.

Lesson 1 • Shutdown and Outage Planning

Covers the additional complexity of planned shutdowns, including scope freeze, critical path, and resource coordination. Builds on standard planning skills.

Lesson 2 • Developing Work Orders

Covers work order creation, priority coding, and scope definition. A well-written work order is the core planning deliverable.

Lesson 3 • Parts, Materials, and Tools Planning

Teaches how to identify and stage required parts, materials, and tools before job execution. Eliminates delays caused by missing resources.

Lesson 4 • The Planning Function Explained

Distinguishes planning from scheduling and defines the planner role. Establishes why structured planning reduces wasted labour and delays.

Lesson 1 • Personal Protective Equipment Selection

Guides selection of appropriate PPE for common maintenance tasks based on hazard type. PPE is the last line of defence in the hierarchy of controls.

Lesson 2 • Permit-to-Work Systems

Explains the structure and purpose of permit-to-work systems for high-risk maintenance tasks. Students complete sample permits for confined space and hot work.

Lesson 3 • Lockout/Tagout and Energy Isolation

Covers energy isolation procedures for electrical, mechanical, hydraulic, and pneumatic energy sources. Proper isolation prevents contact with hazardous energy.

Lesson 4 • Hazard Identification in Maintenance

Teaches systematic hazard identification methods specific to maintenance environments. Recognizing hazards is the first step in any safe work process.

Lesson 1 • Visual and Ultrasonic Inspection

Covers structured visual inspection routines and ultrasonic leak and bearing detection. Builds practical inspection skills applicable to most asset types.

Lesson 2 • Vibration Analysis Fundamentals

Introduces vibration measurement, frequency analysis, and common fault signatures. Connects vibration patterns to specific mechanical defects.

Lesson 3 • Inspection Data Management

Explains how to record, trend, and act on inspection data over time. Connects condition monitoring outputs to the planning and scheduling process.

Lesson 4 • Thermography and Thermal Inspection

Covers infrared thermography for detecting electrical and mechanical heat anomalies. Students identify thermal patterns indicating developing faults.

Lesson 1 • Lubricant Types and Selection

Surveys oils, greases, and specialty lubricants and their application domains. Students match lubricant type to equipment requirements.

Lesson 2 • Lubrication Programme Design

Guides students through building a site lubrication schedule with routes, intervals, and quantities. Integrates lubrication into the broader PM programme.

Lesson 3 • Lubricant Storage and Contamination Control

Addresses proper lubricant storage, handling, and contamination prevention. Contamination is a leading cause of premature lubricant and component failure.

Lesson 4 • Lubrication Application Methods

Covers manual, automatic, and centralised lubrication delivery systems. Correct application method prevents both under- and over-lubrication.

Lesson 1 • Core Maintenance KPIs

Defines essential KPIs including availability, MTBF, MTTR, and PM compliance. Students calculate each metric from sample data sets.

Lesson 2 • Data Collection and CMMS Reporting

Explains how computerised maintenance management systems capture and report KPI data. Accurate data entry is prerequisite to valid metrics.

Lesson 3 • Cost Metrics and Budget Tracking

Covers maintenance cost per unit, cost of unreliability, and budget variance analysis. Links financial data to maintenance decision-making.

Lesson 4 • Benchmarking and Target Setting

Introduces industry benchmarking sources and the process of setting realistic performance targets. Targets drive continuous improvement efforts.