Maintenance Management Mastery: Planning, KPI, CMMS & Safety

Name: Maintenance Management Mastery: Planning, KPI, CMMS & Safety
Rating: 4.5 (20 reviews)

Learn Maintenance Planning, Scheduling, KPI Analysis, CMMS, MTBF, MTTR, OEE, Reliability Engineering & Workplace Safety

Created byRobert Witczak

Last updated 5/2026

English

English [Auto],

What you'll learn

Optimize spare parts inventory to reduce costs while ensuring reliability.
Conduct effective post-failure analysis to identify root causes and improve system reliability.
Understand and apply key maintenance KPIs such as MTBF, MTTR, and availability to enhance processes.
Plan and schedule maintenance activities for maximum efficiency and minimal downtime
Recognize workplace hazards in maintenance and apply proper protective measures.
Implement LOTOTO systems, safety matrices, and Heinrich’s Pyramid to improve safety culture.

Course content

4 sections • 38 lectures • 2h 12m total length

Overview0:49
By the end of this section, students will understand the structure of a maintenance department, its core roles and responsibilities, the main maintenance processes, spare parts management practices, inventory policies, and the identification of critical materials. They will also learn how to apply failure analysis and continuous improvement techniques to enhance department performance.
Structure of the maintenance department4:51
Learn how department size, scope, and staffing models shape roles, responsibilities, and reporting lines in maintenance.
Maintenance Processes3:14
Understand the full maintenance workflow—from request submission, planning, and execution to reporting and analysis.
Spare Parts Management3:05
Master strategies for stocking, sourcing, and optimizing critical spare parts to minimize downtime and costs.
Inventory Policies14:01
Explore Min–Max, JIT, ABC, Safety Stock, Cycle Counting, Kanban, and Consignment policies with practical applications.
Critical Materials3:17
Identify and classify strategic spare parts essential for reliability and cost control in your organization.
Communication1:09
Discover effective collaboration methods between maintenance and production to ensure smooth operations
Continuous Improvement4:28
Use KPIs, analytical methods, and training to drive ongoing performance gains in maintenance activities.
Summary1:30
Summary
Quiz for Module 3: "Structure and Operation of the Maintenance Department"

Overview1:13
This lesson introduces key maintenance performance indicators: OEE, MTBF, MTTR, availability, reliability, and others. You’ll learn their definitions, calculations, and practical uses in improving maintenance results.
Why Measure Maintenance Performance?1:18
Learn why measuring maintenance effectiveness is essential for controlling costs, improving reliability, and optimizing resource use. Understand the risks of not tracking performance.
Key Performance Indicators (KPI)1:20
Discover what KPIs are, how to select the right ones for your organization, and how they support continuous improvement in maintenance.
OEE – Overall Equipment Effectiveness3:16
Understand OEE as a combined measure of availability, performance, and quality. Learn how to calculate it and use it to identify productivity losses.
MTBF – Mean Time Between Failures4:09
Learn how MTBF measures the average operational time between breakdowns, how to calculate it, and how it helps in improving reliability strategies.
MTTR – Mean Time To Repair1:19
Understand MTTR as a measure of how quickly failures are fixed. Learn to calculate it and apply the insights to reduce downtime.
Availability4:29
Explore how availability reflects equipment readiness for production, how it is calculated, and how it links to other KPIs.
Other Maintenance Indicators6:56
Get to know additional KPIs like: PM Compliance, Failure Rate, Total Maintenance Cost and others
Summary2:16
Summary
Quiz for Module 4: " Key indicators and maintenance efficiency“

Overview0:44
Learn how to plan and schedule maintenance tasks effectively – from identifying work sources to using CMMS – to boost efficiency, minimize downtime, and improve machinery reliability.
Planning and Scheduling in Maintenance0:48
Introduction to the role of planning and scheduling in improving maintenance efficiency, reliability, and resource use.
Benefits of Planning and Scheduling0:59
How effective planning reduces downtime, optimizes labor, and improves cost control in maintenance operations.
Types of Work Covered by Planning and Scheduling1:59
Overview of planned work categories, including preventive, predictive, corrective, and improvement tasks.
Elements of a Good Plan1:24
Key components of an effective maintenance plan – resources, tools, procedures, safety, and time estimation.
Differences Between Planning and Scheduling1:44
Clear distinction between planning (what, how) and scheduling (when, who) to improve coordination.
Sources of Work for the Schedule5:11
Where scheduled tasks come from: inspections, failure analysis, predictive monitoring, and improvement projects.
“Wrench Time” – Productive Maintenance Time3:57
Understanding and improving the percentage of time technicians spend on actual repair and maintenance tasks.
CMMS – Computerized Maintenance Management System10:18
Introduction to CMMS as a tool for planning, scheduling, tracking work orders, and optimizing maintenance processes.
Summary0:53
Summary
Quiz for Module 5: "Planning and Work Organization in Maintenance"

Overview0:46
An introduction to health and safety in maintenance — the risks technicians face and how to control them using safeguards, safe procedures, and informed decisions.
Hazards and Health & Safety in Maintenance2:40
Overview of key hazards in maintenance work and core H&S principles to protect people, equipment, and processes.
Technical Safety Measures – LOTOTO2:30
Learn how Lockout-Tagout-Tryout procedures isolate energy sources and prevent accidental machine start-up.
Other Technical Safety Measures16:18
Explore guards, sensors, interlocks, and other devices designed to physically prevent access to danger zones.
Safety Matrix – A Systemic Approach3:51
Understand how to use a Safety Matrix to evaluate risks and determine the right protective measures for each task.
Organizational Aspects of Safety in Maintenance5:34
Discover how procedures, work permits, supervision, and training create a safe working environment.
Heinrich’s Safety Pyramid2:46
Learn the relationship between near misses, minor incidents, and major accidents, and how to reduce all three.
Common Potentially Hazardous Events in Maintenance3:38
Identify frequent near-miss situations in maintenance and the strategies to eliminate their root causes.
Safety Culture1:39
See how building a shared safety mindset improves reporting, awareness, and long-term accident prevention.
Summary1:41
Summary
Quiz for Module 6: "Health & Safety in Maintenance Work"

Requirements

No prior experience in maintenance is required. Basic understanding of industrial operations will help, but all key concepts are explained from the ground up.

Description

Take your maintenance management skills to the next level with this practical and industry-focused course designed for maintenance professionals, engineers, technicians, planners, supervisors, and students who want to build strong expertise in modern maintenance operations.

This course goes beyond basic maintenance concepts and teaches you how to improve equipment reliability, reduce downtime, optimize maintenance planning, and increase operational efficiency using proven real-world maintenance strategies.

You will learn how maintenance departments are structured, how maintenance planning and scheduling work, how to use maintenance KPI effectively, and how to implement workplace safety procedures used in modern industries worldwide.

The course also covers CMMS fundamentals, preventive maintenance strategies, reliability engineering concepts, spare parts management, and post-failure analysis techniques used by maintenance professionals in manufacturing, industrial plants, utilities, oil and gas operations, and production environments.

Throughout the course, you will gain practical knowledge of key maintenance metrics including OEE (Overall Equipment Effectiveness), MTBF (Mean Time Between Failures), MTTR (Mean Time To Repair), equipment availability, maintenance KPI analysis, and reliability improvement strategies.

You will also understand the difference between maintenance planning and scheduling, how to improve workforce efficiency, increase wrench time, organize maintenance activities, and optimize maintenance execution using structured maintenance processes.

Advanced maintenance safety practices are also included, covering Lockout/Tagout (LOTO) procedures, technical safeguards, organizational safety measures, workplace safety culture, and risk reduction strategies.

Based on over 17 years of professional maintenance experience, this course focuses on practical methods that can be applied immediately in real industrial environments.

Whether you are preparing for a maintenance management role, improving your technical maintenance skills, working toward reliability engineering knowledge, or planning to pursue certifications like CMRP, this course provides a strong foundation for success.

*This course contains the use of artificial intelligence.*

Some images, audio narration, and translations were created with the assistance of AI tools (e.g., ChatGPT, Ideogram, ElevenLabs, translation software). All materials have been reviewed and verified by the instructor to ensure accuracy and educational value.

Who this course is for:

Maintenance Managers, Maintenance Planners, Maintenance Engineers, Reliability Engineers, Maintenance Supervisors, Industrial Technicians, Mechanical Engineers, Manufacturing Professionals
This course is also ideal for those who want to start a career in maintenance and need the knowledge to understand how modern maintenance operations work.
Engineering Students, Technical School Students, Professionals preparing for CMRP-related knowledge,

Maintenance Management Mastery: Planning, KPI, CMMS & Safety

What you'll learn

Explore related topics

Course content

Structure and Operation of the Maintenance Department9 lectures • 36min

Key indicators and maintenance efficiency9 lectures • 26min

Planning and Work Organization in Maintenance10 lectures • 28min

Health & Safety in Maintenance Work10 lectures • 41min

Requirements

Description

Who this course is for: