Planned Maintenance

Who owns itMaintenance managers and supervisors

What it targetsRaise the effectiveness of maintenance work, so that production loses nothing to it

What the job isDraw up the daily maintenance plan · Draw up the time-based maintenance plan · Draw up the preventive maintenance plan · Extend the working life of the equipment · Control the replacement of parts to the intervals set · Analyse the failures that occur and find the way to prevent them · Control lubrication

Planned maintenance is the maintenance department’s activity and one of the pillars of TPM — while production runs individual improvement and the operators run autonomous maintenance.

Planned maintenance is everything the maintenance department does to keep the machine usable at all times: work that raises availability, and work that builds maintainability. It divides into preventive, predictive and corrective maintenance, maintenance prevention, and breakdown maintenance.

It is applied to a model machine and model components first, then extended until it covers every machine in the plant. It also needs supporting activity: helping operators with autonomous maintenance, corrective-maintenance work, maintenance prevention, and predictive maintenance.

1. Keeping the machine usable at all times

This is the work that raises availability and maintainability. The maintenance types that serve them are these.

Purpose	Type of maintenance
To stop failure	Preventive Maintenance Predictive Maintenance
To prevent failure	Corrective Maintenance Maintenance Prevention
To be ready when failure comes	Breakdown Maintenance

2. The management side of maintenance

So that planned maintenance is properly supported — with machine data, with spare parts, with budget — there has to be management activity alongside it:

Maintenance information management
Spare part management
Maintenance cost management

3. Support from production

For maintenance to achieve what TPM intends, maintenance and production have to run these activities together. What production contributes is:

Autonomous maintenance
Individual improvement

What it produces

Taken together, planned maintenance raises productivity by improving output — expressed as the pursuit of zero failure, zero defect and zero accident — while at the same time reducing the input maintenance consumes.

Why this pillar is necessary

Planned maintenance is one of the pillars of TPM and is the maintenance department’s responsibility. It exists so that the maintenance work lying outside what the operator does — breakdown, preventive and corrective maintenance — is carried out completely and at the proper intervals, alongside managing the spares, supporting the autonomous maintenance activity, and managing the maintenance database.

Reference

ธานี อ่วมอ้อ. การบำรุงรักษาด้วยตนเอง. กรุงเทพฯ: สถาบันเพิ่มผลผลิตแห่งชาติ, 2547.
ธานี อ่วมอ้อ. การบำรุงรักษาทวีผลแบบทุกคนมีส่วนร่วม. พิมพ์ครั้งที่ 2. กรุงเทพฯ: สถาบันเพิ่มผลผลิตแห่งชาติ, 2546.
Development Program: Implementing Total Productive Maintenance. Tokyo: Japan Institute of Plant Maintenance, 1996.