Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with machine breakdowns. As one of the key pillars of the TPM Excellence framework, the goal of Planned Maintenance is to have trouble-free equipment that produce defect-free products. Planned Maintenance achieves and sustains availability of machines at an optimum maintenance cost, reduces spares inventory, and improves reliability and maintainability of machines. In this presentation developed by our JIPM-certified TPM Instructor, you will learn how to plan and organize the Plan Maintenance activities to strengthen the capabilities of your Maintenance department. It clarifies the roles of the Operations and Maintenance departments in supporting the TPM initiative and provides step-by-step guidance on the implementation of the Planned Maintenance pillar. LEARNING OBJECTIVES 1. Understand what is Planned Maintenance and why it is important in TPM implementation 2. Acquire knowledge on how to plan and organize Planned Maintenance activities 3. Describe the seven implementation steps of Planned Maintenance 4. Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance CONTENTS 1. Introduction to Planned Maintenance 2. What is Planned Maintenance? 3. Planning & Organizing for Planned Maintenance 4. The 7 Steps of Planned Maintenance 5. JIPM TPM Excellence Criteria for Planned Maintenance To download this complete presentation, goto: https://www.oeconsulting.com.sg/training-presentations

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© Operational Excellence Consulting. All rights reserved.
Planned Maintenance

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Learning Objectives
Understand what is
Planned
Maintenance and
why it is important in
TPM implementation
Describe the seven
implementation
steps of Planned
Maintenance
Acquire knowledge
on how to plan and
organize Planned
Maintenance
activities
Gain knowledge on
the JIPM TPM
Excellence Criteria
for Planned
Maintenance
NOTE: This is a PARTIAL PREVIEW.
To download the complete presentation, please
visit: https://www.oeconsulting.com.sg

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Contents
What is Planned Maintenance?
2
Planning & Organizing for Planned Maintenance
3
The 7 Steps of Planned Maintenance
4
JIPM TPM Excellence Criteria for Planned
Maintenance
5
Introduction to Planned Maintenance
1

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The Vicious Cycle Of Poor Equipment Reliability
High frequency
of equipment
breakdowns
Extensive
emergency
repairs
No time for Planned
Maintenance
activities
Fire-fighting
?
UNHAPPY
CUSTOMER
POOR
RELIABILITY
Does your maintenance department look like this?

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From PM to TPM
Productive
Maintenance
Preventive
Maintenance TPM
Traditional PM
Centered in maintenance
departments
PM in TPM
Everyone takes part
Originated in the United States Developed in Japan
(Commonly called “PM”)
Source: Based on JIPM

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© Operational Excellence Consulting. All rights reserved. 6
“Minimizing manufacturing costs is achieved primarily
by improving the productivity of all the machines on
the factory floor, both bottleneck and non-bottleneck
machines alike. This is a daunting challenge unless the
entire organization pitches in and applies proven
methods to the task.”
JAMES A. LEFLAR
Author of “Practical TPM”

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What Is TPM?
TPM addresses the
entire production
system life cycle and
builds a concrete,
shop-floor based
system to prevent all
losses. Its aims
include the
elimination of all
accidents, defects
and breakdowns.
The goal of TPM is
to build a robust
enterprise by
maximizing
production system
efficiency (overall
effectiveness)
TPM involves all
departments, from
production to
development, sales,
and administration
Everyone
participates in TPM,
from top executives
to shopfloor
employees
TPM achieves zero
losses, through
overlapping team
activities
Maximize
efficiency
Entire equipment
life cycle
Coordinates all
departments
Involves
everyone
Team-based
activities

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Planned Maintenance Is One Of The Foundational
Pillars Of TPM
Overview of TPM
Office
TPM
Safety,
Health
&
Environment
Autonomous
Maintenance
Planned
Maintenance
Focused
Improvement
Early
Equipment
Management
Quality
Maintenance
Education
&
Training
5S & Visual Management
TPM Goals:
Zero Defects, Zero Breakdowns,
Zero Accidents
Planned Maintenance aims to increase production
efficiencies by eliminating breakdown losses.

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Difference Between Failure & Breakdown
Failure
§ A failure occurs when
equipment condition
reaches an unacceptable
level, even if it remains
functional
§ This is a failure because
even though the equipment
is still functional, the subpar
condition affects output and
creates a precedent for
breakdown — dubbed the
failure developing period
Breakdown
§ A breakdown occurs when
the equipment stops
functioning
§ Breakdown is the result of
failure and the effect that
failure has over the failure
developing period
§ For example, if the
temperature of your electric
motor remains too high, it
can cause the shaft to snap,
creating a breakdown

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TPM – Three Principles Of Prevention
Maintenance Of
Normal Conditions
To maintain normal operating
conditions, operators prevent
deterioration by cleaning,
checking, oiling, tightening, and
precision-checking the
equipment on a daily basis
Early Discovery Of
Abnormalities
While performing these activities,
operators use their senses and
measurement tools to detect
abnormalities as soon as they
appear. Maintenance workers
also conduct periodic diagnostic
tests to check for abnormalities
using specialized tools.
Prompt
Response
Operators and maintenance staff
respond immediately to
abnormalities

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What Is Planned Maintenance?
Planned Maintenance is a proactive
approach to maintenance that focuses on
minimizing the downtime and costs
associated with breakdowns.

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The Basic Idea Of Planned Maintenance:
Fix It Before It Breaks

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Dual Focus of Planned Maintenance
Improvement of
Equipment
Improvement of
Maintenance Skills

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Difference Between Planned And Preventive
Maintenance
§ The terms planned and preventive maintenance are often used
somewhat interchangeably, but they are not the same thing
§ Preventive maintenance
• Is the most common type of planned maintenance
• It refers to maintenance tasks that you schedule and perform while an
equipment is still working to prevent it from failing unexpectedly
§ Planned maintenance
• Refers to any strategy where you plan and perform maintenance tasks
before a fault occurs

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Difference Between Autonomous Maintenance and
Planned Maintenance
Autonomous
Maintenance
§ Prevents accelerated
deterioration of machine
parts
§ Provides the underpinning
to uphold the benefits of
routine maintenance and
Focused Improvement over
the long term
§ Performed by operators
Planned
Maintenance
§ Prevents unplanned
breakdown losses
§ Addresses specific
equipment-related losses
that reduce OEE
§ Uses data for analysis and
planning
§ Performed by maintenance
personnel

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Benefits of Planned Maintenance
Reduces Spares
Inventory
Reduces inventory through
better control of wear-prone
and failure-prone parts
Enables Maintenance
Planning
Enables most maintenance
to be planned for times
when equipment is not
scheduled for production
Reduces Unplanned
Downtime
Significantly reduces
instances of unplanned
downtime

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Policy of Planned Maintenance
§ Achieve and sustain availability of
machines
§ Optimum maintenance cost
§ Reduces spares inventory
§ Improve reliability and
maintainability of machines

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Planned Maintenance – Two Main Activities
§ Preventive Maintenance
§ Corrective Maintenance
§ Maintenance Prevention
§ Breakdown Maintenance
§ Support for Autonomous Maintenance
§ Specialized maintenance skills
§ Equipment repair skills
§ Inspection and measurement skills
§ Equipment diagnostic skills
§ Develop new maintenance technologies
IMPROVEMENT OF EQUIPMENT
à MTBF
IMPROVEMENT OF MAINTENANCE
SKILLS
à MTTR

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Planned Maintenance Provides A System To Achieve The
Natural Life Cycle Of Individual Equipment Elements
§ Correct operation
§ Correct set-up
§ Cleaning
§ Lubrication
§ Retightening
§ Feedback and repair of minor
defects
§ Quality spare parts

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Elements Of A General Maintenance Plan
1. Maintenance vision and
mission statements
2. Maintenance tasks
3. Standard operating
procedures
4. Maintenance schedule
5. Maintenance staffing and
skills development
6. Spare parts management
7. Engineering and third-party
contractors

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TPM Implementation Organization Structure With Planned
Maintenance Pillar
TPM
Responsible
(Plant
Manager)
Planned
Maintenance
Focused
Improvement
Education &
Training
Autonomous
Maintenance
Safety,
Health &
Environment
Early
Equipment
Management
Office
TPM
Quality
Maintenance
TPM
Promotion
Office
The company
should focus on
these four pillars
during the first
three years of TPM
implementation

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Tasks for Maintenance Department
§ Tasks requiring special skills
(beyond the capability of operators)
§ Overhaul repair in which
deterioration is not visible from the
outside
§ Repairs to equipment that is hard
to disassemble and reassemble
§ Tasks requiring special
measurements
§ Tasks posing substantial safety
risks, such as working in high
places
Source: TPM for Workshop Leaders by Kunio Shirose

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Key Roles Of Operations & Maintenance Divisions
Operations maximizes
production outputs
through efficient use of
resources and takes
responsibility for
routine maintenance
Maintenance
increases equipment
reliability and
minimizes maintenance
cost by reducing
breakdowns and
developing efficient
maintenance methods
Operations Maintenance
Operations and Maintenance have tremendous ability to
impact profitability through collaboration and change.

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Roles Of The Maintenance Department
Figure 2: Roles of the Maintenance Department
Maintenance Activities to be Performed
Maintenance Classification Preventing Deterioration Measuring Deterioration Rectifying Deterioration
Periodic Maintenance
Periodic inspection
Periodic examination
Periodic shutdown
Predictive Maintenance Trend control Unscheduled shutdown
Sporadic repair
Breakdown Maintenance
Early detection of situation and
speedy countermeasures
Corrective Maintenance
(Reliability)
Enhancement of material strength
Reduction of load
Enhancement of accuracy
Corrective Maintenance
(Maintainability)
Development of condition monitoring Improvement of maintenance work
Improvement of inspection work
Enhancement of maintenance
quality

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Maintenance & Control
§ Improvements in MTBF are
accomplished through the support of
AM activities and the implementation
of the four maintenance types
discussed previously:
• Breakdown maintenance
• Periodic maintenance
• Predictive maintenance
• Corrective maintenance

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The 4 Phases to Zero Breakdowns
Phase 1
Eliminate forced
deterioration
Phase 2
Extend lifetimes
through corrective
maintenance
Phase 3
Monitor and
control
deterioration
Phase 4
Carry out
predictive
maintenance

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The 7 Steps Of Planned Maintenance
Provide Support And Guidance To
Autonomous Maintenance Activities
Evaluate Equipment And Understand Current
Condition
Restore Deterioration And Correct Weaknesses
Build An Information Management System
Build A Periodic Maintenance System
Build A Predictive Maintenance System
Evaluate The Planned Maintenance System
1
2
3
4
5
6
7

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Step 3 – Restore Deterioration And Correct Weaknesses
§ Extend help to operators to prepare ‘tentative standards’ for
cleaning, lubrication and inspection for each machine
§ Specify clearly what the operators are supposed to do under
Autonomous Maintenance and what the maintenance engineers are
supposed to do under Planned Maintenance
§ Use provisional standards for checking and replacement intervals
§ Examine each machine and identify the parts that should be
subjected to preventive maintenance
§ Establish schedules for TBM and CBM

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How to Sustain TPM & Planned Maintenance Activities
§ Providing active leadership
§ Engaging employees
§ Aim for early success
§ Share success stories
§ Rewards and recognition
§ Continuously reduce equipment
losses
§ Evolving the TPM initiative over time
and integration with Lean

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Operational Excellence Consulting is a management training and consulting
firm that assists organizations in improving business performance and
effectiveness. Based in Singapore, the firm’s mission is to create business
value for organizations through innovative design and operational excellence
management training and consulting solutions. For more information, please
visit www.oeconsulting.com.sg