Planned Maintenance Pillar Workshop

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Planned Maintenance – Introduction


  • Provide an overall understanding of Planned Maintenance
  • Facilitate the site in developing and refining PM plan
  • Identification of additional training requirements

Develop an understanding of:


  • Develop a 3 Year Pillar Master Plan
  • Detail for each of the 8 PM elements
  • Pillar Goals, Targets and KPI’s


  • Presentation of workshop results to Site Steering Committee

TPM Health Check

  • Must be able to plan, organize, lead and control;
  • Planning the work by predetermining the expected quality and quantity of output for every job;
  • Organize the work by specifying the appropriate ways and means to perform each task;
  • Leading and influencing others to engage in work behaviours to achieve the desired results;
  • Controlling the work by:
    • selecting and training qualified individuals;
    • overseeing the actual job performance;
    • verifying that the output meets the expectations.


To establish and maintain optimal equipment and process conditions, cost effectively and efficiently.


(1) PM and AM clearly defined. Both maintain the equipment with shared responsibilities.

(2) Time Based Maintenance (TBM) and Condition Based Maintenance (CBM) are being selectively used.

(3) Specialized maintenance techniques  such as lubrication control and root cause analysis are being used .

(4) Reliability, maintainability and availability are being measured.

(5) Corrective maintenance is pursued and utilized in the creation of MPs.

(6) Maintenance equipment is under controlled.

(7) Data concerning downtime, man hours, MTBF, MTTR, etc is being analyzed .

(8) CMMS is being effectively utilized.

(9) Equipment diagnosis techniques are studied and used.

(10) Maintenance costs are understood and controlled.

The 6 steps for effective maintenance

Step 1. Evaluate and understand current conditions

  • Prepare or update machine log
  • Evaluate and prioritize the equipment
  • Rank failures
  • Understand the failure situation and set maintenance goals

Step 2. Restore deterioration & correct weaknesses

  • Help operators restore the equipment
  • Correct weaknesses and lengthen equipment life using focused improvement methods
  • Prevent recurrent major failures

Step 3. Build an information system

  • Build a failure data management system
  • Build a system for controlling parts and materials
  • Build a system for controlling technical information

Step 4. Build a periodic maintenance system

  • Select equipment and components for periodic maintenance
  • Prepare maintenance plans
  • Formulate periodic maintenance standards

Step 5. Build a Predictive maintenance system

  • Select key equipment for predictive maintenance
  • Introduce equipment diagnostics
    • Vibration,Temperature,Lubricant sampling
  • Roll out to other equipment

Step 6. Evaluate the maintenance system

  • Evaluate improvement on
    • reliability
    • maintainability
    • maintenance cost savings
  • Review the whole system


The concept of Planned Maintenance is designed to lower costs through conducting maintenance efficiently and eliminate breakdowns by enhancing equipment effectiveness.

Continuously improving maintenance activities and performing them in a systematic, efficient and effective  manner.


A step by step approach for achieving zero breakdowns:

  • Return to and maintain the equipment in its basic condition
  • Extend the equipment’s effective service life
  • Prevent future breakdowns
  • Predict equipment’s natural limits

Best Practice

100% – Maintenance persons time is covered  by a work order

90% – Work orders generated through PM inspections

30% – Work is predictive

90% – Planned and scheduled compliance

100% – Capacity reached 100% of the time

  • Spare Part stock-outs less than 1 per month
  • Overtime is less than 2% of total maintenance time
  • Backlog for each trade in each department

+/- 2 %  Maintenance budget within +/- 2%

Approach to Maintenance

RCM Reliability-Centered Maintenance

A process used to determine the maintenance requirements of any physical asset in its operating context…

Self Assessment – Planned Maintenance


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