PLANNED PREVENTIVE MAINTENANCE (PPM)

Planned Preventive Maintenance (PPM) refers to the scheduled servicing of equipment, machinery, or systems to prevent potential failures, reduce downtime, and extend their lifespan. It involves regular inspections, adjustments, repairs, and replacements carried out at predetermined intervals.

 

Objectives of PPM:

• Minimize unexpected equipment failures.
• Extend the lifespan of assets.
• Improve operational efficiency and reliability.
• Ensure compliance with safety standards.
• Reduce long-term maintenance costs.

 

Types of Preventive Maintenance:

1. Time-Based Maintenance (TBM): Performed at scheduled intervals (e.g., monthly, quarterly).
2. Usage-Based Maintenance (UBM): Based on usage metrics (e.g., every 10,000 operating hours).
3. Condition-Based Maintenance (CBM): Triggered by monitoring equipment conditions (e.g., vibration analysis).

 

Key Components of a PPM Program:

• Asset Inventory: Cataloging all assets requiring maintenance.
• Maintenance Schedule: Establishing a calendar for regular servicing.
• Checklists & Procedures: Standardized tasks for inspections and repairs.
• Record Keeping: Documenting maintenance activities and outcomes.
• Review & Improvement: Periodic evaluation of the PPM program’s effectiveness.

 

Benefits of PPM:

• Reduced Downtime: Fewer unplanned breakdowns.
• Cost Savings: Lower repair costs and energy consumption.
• Increased Safety: Ensures equipment operates safely.
• Regulatory Compliance: Meets industry and legal requirements.

 

 

Here's a detailed plan and checklist to help you implement an effective Planned Preventive Maintenance (PPM) program.

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✅ 1. Establish Maintenance Objectives

• Identify the goals (e.g., reduce breakdowns, improve asset life).
• Define key performance indicators (KPIs) (e.g., equipment uptime, maintenance cost reduction).

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✅ 2. Create an Asset Inventory

• List all critical equipment and assets requiring maintenance.
• Include details:
• Asset name and type
• Manufacturer and model
• Serial number
• Location
• Installation date

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✅ 3. Classify Assets by Priority

• High-Criticality: Equipment essential to operations (e.g., HVAC, generators).
• Medium-Criticality: Assets impacting productivity if malfunctioning.
• Low-Criticality: Non-critical assets (e.g., office appliances).

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✅ 4. Develop Maintenance Schedules

• Set frequency:
• Daily/Weekly: Basic inspections (cleaning, lubrication).
• Monthly/Quarterly: Performance checks, minor repairs.
• Annually: Major overhauls, system diagnostics.
• Base schedules on manufacturer guidelines and operational demands.

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✅ 5. Create Maintenance Checklists

Standardize maintenance tasks for each asset. Example:

Example: HVAC System

• Inspect and replace air filters.
• Clean condenser and evaporator coils.
• Check refrigerant levels.
• Inspect electrical connections.

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✅ 6. Implement a Maintenance Tracking System

• Use CMMS (Computerized Maintenance Management System) for automated scheduling and record-keeping.
• Track:
• Work orders
• Maintenance history
• Spare parts inventory

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✅ 7. Conduct Staff Training

• Train maintenance teams on PPM procedures and safety protocols.
• Ensure knowledge of emergency response.

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✅ 8. Monitor and Improve the Program

• Regularly review maintenance logs and performance data.
• Adjust schedules based on equipment performance and failure patterns.

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📋 PPM Checklist Template

 

Task	Frequency	Completed (Y/N)	Notes
Equipment Inspection	Monthly
Lubrication Check	Quarterly
Electrical Testing	Annually
Safety Audit	Bi-Annually