Creating a preventive maintenance plan (step-by-step)

The benefits of preventive maintenance are undeniable. (Honestly, it would be surprising if at this point you were not yet thinking about applying preventive maintenance to your equipment!) The question is how? Where to start? How to create and execute a preventive maintenance plan? Make yourself comfortable, because we have the answers.

The first step in implementing a preventive maintenance strategy is to define a plan. All work orders must be well defined, taking into consideration materials, parts, the necessary labor, and even the hiring of specialized external services. The process can be divided into 5 steps:


1.Setting goals.

To make your preventive maintenance plan really useful, the first step is to set the goals you want to achieve. What do you want? To reduce downtime, increase asset reliability, reduce costs, or increase the planned maintenance rate? What have you done so far to meet these goals? What has failed? This first diagnostic test is your starting point.

2. Make an asset inventory.

For your plan to be comprehensive, you need to map the assets, that is, organize the assets by equipment families and location. Each asset should be linked to the manufacturer’s recommendations, warranties and quality standards to be met.

For example, air conditioning equipment should be grouped into the HVAC equipment family, with the respective location of each appliance and user manuals, as well as the ISO standards (if applicable) to be met.

3. Establish priorities.

Both time and resources are limited. Unfortunately, you are unlikely to be able to perform all the preventive maintenance you would like, so give priority to the most critical assets. Select those assets that are essential to the normal operation of the company, those that can cause high losses, and those that pose the greatest risk in the event of failure.

On this later matter, it is important to establish priorities according to the current conditions of the equipment. A risk assessment is extremely useful to rank the priority level of each asset. The inspection of gas leaks, for example, is always a priority because it puts at risk the safety of all those who use the facilities.

4. Creating KPIs for the maintenance plan.

To know if the plan is meeting its objectives, the maintenance manager has to be able to track events over time. The best way to do this is through performance indicators (KPIs), which we talk about later on in the assessment and review section of the plan.

5. Review and improve the plan.

Even the best things can be improved. Depending on the results you get (measured according to the KPIs you defined), make progressive improvements to the plan.

To put this into practice as quickly as possible, we strongly recommend that you read our expert tips on how to create a maintenance planning

Readmore Preventive Maintenance: The Ultimate Guide [2020]

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