Planned maintenance is one of the concepts of Total Productive Maintenance (TPM). The purpose of planned maintenance is to reduce losses caused by unexpected breakdowns by implementing a plan of preventive and predictive maintenance procedures.
Planned maintenance is one of the eight pillars of TPM. In the process of implementing TPM, maintenance gradually delegates some routine tasks to operators. Operators take responsibility for cleaning, checking, and lubricating equipment, which used to be performed by the maintenance team. This frees up time for maintenance personnel to introduce more sophisticated maintenance approaches based on data collection and analysis from the equipment, leading to planned maintenance interventions. The aim of implementing planned maintenance is to prevent unexpected equipment failures, thus eliminating losses associated with breakdowns and transferring daily equipment care to operators.
The planned maintenance program starts at the beginning of TPM implementation, alongside the autonomous maintenance program. Maintenance gradually hands over responsibilities for routine inspections, minor repairs, cleaning, and lubrication of equipment to production operators. This provides maintenance teams with more time to improve maintenance planning and inventory management using TPM tools.
First, it is essential to gather data on the frequency, severity, and occurrence of equipment failures. Parameters such as MTBF, MTTR, Cm, and Cmk are used for monitoring. Subsequently, machines are categorized into three groups based on their significance:
During the planning process, maintenance plans are defined, which are schedules for equipment interventions. Maintenance plans are categorized according to the type of intervention as routine, intermediate, or comprehensive.
The second mission of planned maintenance is the analysis of unforeseen breakdowns and the implementation of corrective actions to eliminate the root cause of the failure. To perform this analysis, maintenance employees need to deepen their knowledge of the structure and functionality of equipment components, thus increasing the maintenance team's expertise. Gradually, maintenance also learns about the relationship between the equipment's condition and the quality of the output from the equipment. This linkage connects knowledge about machine parameters and product quality parameters. The acquired knowledge is necessary for process quality control.
Two approaches are used for maintenance planning:
Preventive Maintenance: Based on past failure frequency and causes, interventions are planned sufficiently in advance to prevent failure. This approach utilizes predetermined time intervals for equipment interventions, such as replacing a bearing after a certain number of operating hours. The disadvantage of this approach is that it cannot consider the current state of the equipment, which may be significantly different from the state when the time intervals for interventions were defined. It may lead to either premature intervention when the machine doesn't need repair yet or, conversely, intervention planned too late, resulting in an unexpected breakdown.
Predictive Maintenance: This approach works with multiple models of equipment behavior, generally considering different operating conditions. In predictive maintenance, no fixed time for intervention is set; instead, a parameter related to an impending failure is measured. A change in the parameter indicates the need for intervention in a timely manner. For example, the replacement of a bearing may be determined not by operating hours but by vibration characteristics measured on the bearing.
Predictive maintenance is the most demanding method among all approaches to implement, but it provides a much better understanding of equipment operation, allows more reliable prediction of failure, and maximizes equipment utilization.
Planned maintenance also aims to improve the management of spare parts, special tools, and materials needed for specific equipment interventions. Excessive inventory of spare parts or other resources unnecessarily ties up a company's finances and leads to wastage. On the other hand, insufficient resources for service interventions increase maintenance costs in various ways. It extends equipment downtime, disrupts production planning, and ultimately increases costs due to the urgency of delivering the necessary missing resources. For proper management of spare parts and related materials, it is essential to have a thorough understanding of the current state of the equipment, the possible causes that may lead to failure, and knowledge of the functionality of components.
To launch a planned maintenance program successfully, it is crucial to understand not only maintenance processes but also related processes in production and administration. Our company can provide services from experienced trainers and coaches to ensure a successful TPM implementation.
| Training name | Training duration | Venue | Price | The nearest date |
|---|---|---|---|---|
| 5S (7S) – Japanese concept of workplace improvement |
1 day
(8:00 - 14:00)
|
Online |
450,00 €
540,00 € VAT included
|
06.02.2025
+ 3
|
| Statistical Process Control – Basics |
2 days
(8:00 - 14:00)
|
Online |
810,00 €
972,00 € VAT included
|
26.02.2025 - 27.02.2025
+ 3
|
| 5S - Practical workshop |
1 day
|
Company in-house training | On request |
According to you
|
| Innovative methods used in the automotive industry and mechanical engineering |
10 days
|
Company in-house training | On request |
According to you
|
| TPM - Total productive maintenance |
2 days
|
Company in-house training | On request |
According to you
|
| SPC II - SPC Troubleshooting |
2 days
|
Company in-house training | On request |
According to you
|
| SPC III Project of introducing statistical methods in the organization |
2 days
|
Company in-house training | On request |
According to you
|
