TPM: Planned Maintenance Poster (PDF)

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

The goal of Planned Maintenance is to increase equipment reliability and minimize maintenance cost by reducing breakdowns and developing efficient maintenance methods.

The Seven Steps of Planned Maintenance Poster highlights the key activities of Planned Maintenance as a key pillar of the TPM Excellence framework.

The poster comes in two themes: color and monochrome. Formatted in PDF and in editable PPTX, the poster can be easily printed on an A3-sized paper from an office copier machine and displayed at operator workstations, TPM Activity Boards, meeting rooms, maintenance workshop, or distributed together with your workshop handouts.

The poster complements the ‘Planned Maintenance' PPT training presentation materials. It serves as a takeaway and summary of your TPM or Planned Maintenance presentation.

Based on the JIPM* standard, the Seven Steps of Planned Maintenance include:
Step 1 – Provide Support And Guidance To AM Activities
Step 2 – Evaluate Equipment And Understand Current Condition
Step 3 – Restore Deterioration And Correct Weaknesses
Step 4 – Build An Information Management System
Step 5 – Build A Periodic Management System
Step 6 – Build A Predictive Management System
Step 7 – Evaluate The Planned Maintenance System

Details of the steps:

Step 1 – Provide Support And Guidance To AM Activities
•  Participate with operators in putting white and red tags
•  Attend to red tag abnormalities
•  Help Operations department to set up the Autonomous Maintenance pillar infrastructure (e.g. develop one-point lessons)

Step 2 – Evaluate Equipment And Understand Current Condition
•  Identify and correct equipment defects
•  Analyze failures/breakdowns and stratify the causes
•  Conduct why-why analysis
•  Collect baseline data on the number of sporadic failures, MTBF and MTTR

Step 3 – Restore Deterioration And Correct Weaknesses
•  Help operators to prepare ‘tentative standards' for cleaning, lubrication and inspection for each machine
•  Use provisional standards for checking and replacement intervals
•  Establish schedules for TBM and CBM

Step 4 – Build An Information Management System
•  Extend help to operators in education, on-the-job training in general inspection and developing inspection procedures (e.g. using visual controls)
•  Conduct trends analysis based on sporadic failures, MTBF and MTTR data

Step 5 – Build A Periodic Management System
•  Prepare standard documents for material selection, spare parts management, etc.
•  Increase reliability by increasing the number of periodic maintenance items based on deterioration measurements
•  Reduce time and cost of overhauls by standardizing parts, etc.

Step 6 – Build A Predictive Management System
•  Apply equipment diagnostics technology
•  Develop equipment diagnostics skills
•  Use diagnostics to monitor trends and identify points of change
•  Change TBM to CBM

Step 7 – Evaluate The Planned Maintenance System
•  Continue to maintain the equipment in accordance with the standards while progressively enhancing those standards
•  Review and improve the Planned Maintenance system
•  Prepare the Planned Maintenance Master Plan

*Note: The Japan Institute of Plant Maintenance (JIPM) is a nonprofit research, consulting, and educational organization that helps companies increase organizational efficiency and profitability through improved maintenance of manufacturing equipment, processes, and facilities. The JIPM is the sponsoring organization for the TPM Excellence Award, awarded annually to recognize excellence in company-wide maintenance systems. Based in Japan, JIPM is the innovator of methodologies that have been implemented around the world.