What is Planned Maintenance?

Planned maintenance is crucial for ensuring the reliability, efficiency, and safety of equipment and assets within an organization. By proactively scheduling maintenance activities, businesses can minimize unexpected breakdowns, optimize performance, and extend the lifespan of their assets. Planned maintenance revolves around the proactive scheduling and execution of maintenance tasks according to a predetermined plan. Its primary focus is on minimizing unplanned downtime, ensuring smooth operations, and maximizing the utilization of resources such as spare parts, tools, services, and labor.

Two Categories of Planned Maintenance

Preventative Maintenance

Preventative maintenance involves the systematic inspection, detection, and correction of potential issues before they lead to equipment failure. It aims to reduce the likelihood of unexpected breakdowns by performing scheduled tasks such as lubrication, parts replacement, and system adjustments.

Planned Unscheduled Maintenance

Planned unscheduled maintenance anticipates potential failures based on historical data and operational knowledge. While it’s not performed at fixed intervals like preventative maintenance, it’s scheduled in advance to minimize disruptions and control maintenance costs effectively.

Advantages and Disadvantages of Planned Maintenance

Advantages of Planned Maintenance

Decreases Downtime: Planned maintenance reduces the risk of unexpected equipment failures, minimizing downtime and maximizing productivity.
Increases Asset Lifespan: Regular upkeep ensures that equipment operates within optimal parameters, extending its operational life.
Reduces Maintenance Costs: Proactive maintenance helps in identifying issues early, preventing costly repairs and replacements.
Improves Workplace Safety: Well-maintained equipment is less likely to pose safety hazards to personnel, enhancing overall workplace safety.
Enhances Company Culture: Prioritizing maintenance fosters a culture of responsibility, reliability, and efficiency within the organization.

Disadvantages of Planned Maintenance

Risk of Unnecessary Tasks: Over-maintenance can lead to unnecessary expenses and resource allocation if maintenance tasks are not based on actual equipment needs.
Potential Increase in Maintenance Costs: While planned maintenance aims to reduce costs, improper planning or execution may lead to increased expenses due to over-reliance on external services or unnecessary parts replacement.

Steps to Scheduling Maintenance Tasks

Proactive maintenance involves a structured approach to scheduling and executing maintenance tasks:

Identify Equipment Failure Modes: Understand potential failure modes and prioritize maintenance activities accordingly.

Conduct Asset Inspections: Regularly inspect equipment and surrounding environments to identify early signs of deterioration or malfunction.

Define Work Processes: Establish clear procedures for performing maintenance tasks to ensure consistency and efficiency.

Create Priority Levels: Prioritize maintenance tasks based on criticality, safety concerns, and operational requirements.

Schedule Planned Maintenance Program: Develop a comprehensive maintenance schedule that balances operational needs with resource availability and downtime constraints.

Equipments Requiring Planned Maintenance Schedule

Various equipment and assets require planned maintenance to ensure optimal performance and longevity. Common examples include HVAC systems, lighting fixtures, pest control measures, filters, belts, instruments for recalibration, vehicles, and compressors.

What Is Unplanned Unscheduled Maintenance?

Unplanned unscheduled maintenance refers to reactive repairs performed in response to unexpected equipment failures. It typically involves urgent interventions to restore functionality and minimize downtime. Unplanned maintenance disrupts operations, leading to productivity losses, increased repair costs, and potential safety risks. It can negatively impact the organization’s bottom line by inflating maintenance expenses and reducing overall efficiency. Understanding failure modes and their root causes is essential for implementing effective maintenance strategies. By analyzing past failures, organizations can proactively address underlying issues, minimize future breakdowns, and optimize maintenance practices.