Industrial Maintenance Management Course

Lesson 1 • Plant Equipment and Asset Basics

Introduces common industrial equipment categories and their functional roles. Builds vocabulary needed for later technical chapters.

Lesson 2 • Safety Culture in Maintenance

Covers hazard recognition, lockout/tagout principles, and permit-to-work systems. Safety compliance underpins every maintenance activity in this course.

Lesson 3 • Role of Maintenance in Industry

Defines maintenance's contribution to production reliability and asset longevity. Connects organisational goals to daily maintenance decisions.

Lesson 1 • Shutdown and Turnaround Planning

Addresses scope development, critical path scheduling, and resource levelling for planned outages. Turnaround efficiency depends on pre-outage planning rigour.

Lesson 2 • Scheduling Principles and Methods

Covers weekly and daily scheduling logic, backlog management, and schedule compliance metrics. Links planning output to crew deployment.

Lesson 3 • Job Planning Techniques

Teaches systematic job plan development including task sequencing and resource estimation. Well-written plans reduce job duration and rework.

Lesson 1 • Ultrasound and Other PdM Technologies

Covers airborne and structure-borne ultrasound, motor current analysis, and emerging sensor technologies. Selecting the right technology maximises defect detection probability.

Lesson 2 • Vibration Analysis Fundamentals

Introduces vibration measurement, spectrum analysis, and common fault signatures. Vibration data enables early detection of rotating equipment defects.

Lesson 3 • Designing Effective PM Programmes

Covers task selection, interval setting, and PM rationalisation to eliminate over-maintenance. A well-designed PM programme balances cost and reliability.

Lesson 4 • Thermography and Oil Analysis

Explains infrared thermography for electrical and mechanical inspections and oil analysis for lubrication health. Both technologies extend equipment life when applied systematically.

Lesson 1 • Preventive Maintenance Module

Covers PM task list creation, trigger types, and frequency optimisation. Accurate PM records reduce unplanned failures over time.

Lesson 2 • Data Quality and Continuous Improvement

Addresses common data entry errors, audit methods, and governance practices. Clean CMMS data is the foundation for reliability analysis in later chapters.

Lesson 3 • CMMS Architecture and Setup

Explains equipment hierarchy, location structures, and master data requirements. Correct setup determines the quality of all downstream reporting.

Lesson 4 • Work Order Processing in CMMS

Demonstrates end-to-end work order creation, assignment, and closure within a CMMS. Consistent data entry enables reliable cost and performance analysis.

Lesson 1 • Root Cause Analysis Methods

Covers five-why analysis, fishbone diagrams, and fault tree analysis for systematic failure investigation. Eliminating root causes prevents recurrence and reduces costs.

Lesson 2 • Reliability-Centred Maintenance

Introduces RCM methodology for selecting maintenance tasks based on functional failure consequences. RCM optimises task selection across safety, operational, and economic criteria.

Lesson 3 • Failure Mode and Effects Analysis

Guides students through FMEA methodology to identify failure modes, effects, and criticality rankings. FMEA outputs directly inform PM task selection.

Lesson 4 • Reliability Concepts and Metrics

Defines MTBF, MTTR, availability, and reliability distributions. These metrics quantify equipment performance and guide maintenance investment decisions.

Lesson 1 • Storeroom Operations and Layout

Addresses physical storeroom design, receiving procedures, and issue control. An organised storeroom reduces search time and prevents part deterioration.

Lesson 2 • Procurement and Supplier Management

Covers purchase requisition processes, vendor qualification, and long-term supply agreements. Strong supplier relationships reduce lead times and emergency purchases.

Lesson 3 • Spare Parts Classification and Coding

Covers part categorisation by criticality, lead time, and usage frequency. Proper classification drives appropriate stocking and procurement strategies.

Lesson 1 • Capital Investment Justification

Covers net present value, payback period, and life cycle cost analysis for maintenance capital requests. Financial justification skills secure funding for reliability improvements.

Lesson 2 • Maintenance Cost Benchmarking

Introduces industry benchmarking ratios such as maintenance cost as a percentage of replacement asset value. Benchmarks reveal performance gaps and improvement targets.

Lesson 3 • Budget Development and Control

Teaches zero-based and historical budgeting methods, variance analysis, and cost control actions. A controlled budget demonstrates maintenance's financial accountability.

Lesson 1 • Continuous Improvement Frameworks

Introduces Lean, TPM, and Six Sigma concepts applied to maintenance operations. Structured improvement frameworks sustain gains beyond individual projects.

Lesson 2 • Maintenance Metrics and Scorecards

Teaches balanced scorecard design linking maintenance KPIs to safety, quality, cost, and delivery. Scorecards align team behaviour with strategic priorities.

Lesson 3 • Change Management in Maintenance

Addresses resistance to change, stakeholder engagement, and communication planning for maintenance transformations. Sustainable change requires deliberate people-side management.

Lesson 4 • Maintenance Excellence Roadmap

Guides students through maturity assessment, gap analysis, and multi-year improvement planning. A documented roadmap translates strategy into executable maintenance initiatives.