What is Planned Maintenance?

What is Planned Maintenance Work?

Planned maintenance is a planned, documented and programmed maintenance technique for the maintenance of machinery and equipment. The technique aims to eliminate the high costs of repairing machinery and equipment malfunctions, reduce downtime, reduce the risk of accidents and ensure maximum efficiency in production.

The planned maintenance process begins by identifying a problem that is desired to be addressed, such as extending downtime or the life of machinery and equipment. It then continues with identifying, planning and documenting the steps that will achieve the goal.

What are the Types of Planned Maintenance?

There are two types of planned maintenance: planned preventive maintenance and planned unplanned maintenance.

Planned Preventive Maintenance

Planned preventive maintenance ensures that machinery, equipment or assets are repaired before they fail. It is a process that helps prevent unexpected equipment failures, shorten downtime, reduce costs and ensure regular maintenance of equipment. Uses industry standards to determine how maintenance routines should be performed to prevent malfunctions. The maintenance routine is generally created based on time, duration of use or condition of the equipment.

Examples of Planned Preventive Maintenance

  • Oil and filter changes
  • Tire rotation
  • Brake inspection,
  • Pad replacement,
  • Fluid controls

Planned Unscheduled Maintenance

It refers to postponing the maintenance plan of an asset until any malfunction occurs. Also known as maintenance until failure. This type of maintenance is used for assets that have little or no role in the production taking place. Therefore, these assets do not need to be replaced or maintained in advance.

Planned Unscheduled Maintenance Examples

  • Electric drills
  • Measuring instruments
  • Short-lived assets
  • Assets with low financial value

What is the Difference Between Planned Maintenance and Preventive Maintenance?

Planned maintenance and preventive maintenance are often used interchangeably. However, there is a fundamental difference between them.

In planned maintenance, maintenance tasks are planned and carried out before a malfunction occurs. Preventive maintenance involves planning and implementing maintenance tasks while the machinery is in operation to prevent unexpected malfunctions.

Advantages & Disadvantages of Planned Maintenance

Let’s examine the advantages and disadvantages of planned maintenance in production processes:

Advantages of Planned Maintenance

  • It reduces downtime by enabling teams to solve problems with machinery and equipment before they cause malfunctions.
  • Since the equipment is maintained regularly, the lifespan of the equipment increases.
  • It greatly reduces the costs spent on maintenance.
  • Equipment operating under optimum conditions prevents an unexpected accident. Thus, it ensures the safety of employees using the equipment.
  • Interruptions in the production process can stress employees and reduce their motivation. Planned maintenance minimizes downtime, supporting everyone’s happy work.

Disadvantages of Planned Maintenance

The biggest disadvantage of planned maintenance occurs when the equipment to be maintained does not need maintenance. In such a case, the maintenance technician will not be able to undertake a more urgent task and will waste his time on equipment that does not require maintenance anyway.

How to Implement Planned Maintenance?

The steps to creating a sustainable planned maintenance program are as follows:

Identify Equipment Failure Modes

In the first stage, you should outline the general content of the work to be completed. Collect failure modes related to the relevant asset and any data that may be useful in the maintenance process. Failure modes describe situations in which assets and their components may fail in certain ways.

Perform Asset and Environmental Audit

Determine general details of maintenance tasks to be performed in case of failure. In this step, you should ask yourself these questions:

  • What tools will be needed?
  • Which spare parts should be kept?
  • Are there any operating environment factors that may affect the maintenance process?

Define Business Process

In this step, you need to document the maintenance process of the asset step by step. In this document, you should include a standard operating procedures that includes important information such as safety precautions and shutdown procedures.

Create Priority Levels

If you have a planned and repeated work order, prioritizing it provides great convenience. Always prioritize tasks that get facilities to optimal operating levels in the shortest time possible.

Plan Planned Maintenance Schedule

As a final step, assign maintenance tasks to the relevant technicians and give them this responsibility.

If you are interested in this blog, “How to Implement Autonomous Maintenance?” You may also be interested in the blog called.

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