Planned Maintenance Step 1, 2 & 3

In general, it is observed that the maintenance team is quite occupied or busy with restoration activities and they hardly find time to indulge in Improvement activities. Also, the “one-size-fits-for-all” syndrome of conducting preventive maintenance once a month for the whole equipment while the equipment is a combination of multiple spare-parts whose life behaviour are different from each other. The Planned Maintenance pillar activities are normally led by the maintenance team.

Planned Maintenance is the third pillar of TPM. This pillar aims to achieve zero unplanned breakdowns. It follows a structured approach to establish a management system that extends the equipment reliability at optimum cost.​

The 7 step methodology of planned maintenance is briefly explained and a deep-dive exercise is done for the first 3 steps. Prioritising the equipment, evaluating the current maintenance practices & costs will be detailed. The need of building an Information management systems as to ascertain the effectiveness of maintenance activities and how to do the same will also be addressed.

The attendees will learn the optimum approach to maintaining the equipment, starting with a Periodic Maintenance (Time-Based Maintenance) system before introducing Predictive Maintenance (Condition-Based Maintenance) systems where they are appropriate and cost-effective. In a nutshell, the team will be prepared to eliminate reactive activities and assure equipment reliability.

The purpose of Keikaku Hozen (Planned Maintenance) training program is to make the attendees enable practice and implement Planned Maintenance in their facility as to ensure reliable equipment (with zero failures and quality defects) and to do so efficiently, at minimum cost