Planned Maintenance organizes preventive, predictive, corrective, and improvement maintenance work so equipment reliability is managed before failure disrupts operations.
Definition
Planned Maintenance is a TPM and maintenance-management pillar focused on intentionally scheduling, preparing, executing, and improving maintenance work. It includes preventive maintenance, predictive maintenance, planned corrective work, spare-parts readiness, maintenance standards, and failure history analysis.
The objective is to reduce unplanned downtime, stabilize equipment condition, and improve lifecycle performance.
History
Planned Maintenance evolved from preventive maintenance, reliability engineering, and TPM. Early maintenance systems were often reactive; TPM connected maintenance planning with operator care, focused improvement, and equipment-loss reduction.
When to Use
Use Planned Maintenance when breakdowns, minor stops, repeat failures, spare-parts delays, or emergency work disrupt flow. It is also needed when equipment risk affects safety, quality, delivery, or regulatory compliance.
Step-by-Step
- Rank assets by criticality and risk.
- Collect failure history, downtime, repair time, and condition data.
- Define maintenance tasks by failure mode and operating context.
- Set frequencies using data, OEM guidance, and experience.
- Prepare parts, tools, skills, permits, and procedures.
- Schedule work with production and operations.
- Measure compliance, breakdowns, MTBF, MTTR, and repeat failures.
- Improve plans using root cause and loss data.
Examples
- Preventive: Scheduled lubrication and inspection prevent bearing failure.
- Predictive: Vibration analysis triggers planned repair before breakdown.
- Corrective: A known leak is repaired during a planned window instead of emergency downtime.
Common Pitfalls
- Calendar-based PMs that do not match failure modes.
- No criticality ranking.
- Poor coordination with production schedules.
- Missing parts or unclear job plans.
- Measuring PM completion but not failure reduction.
- No feedback loop from technicians.