In today's world of ever-increasing competition and rapid change, it's crucial for organizations to establish a solid foundation and continuously improve themselves to survive and achieve success. One of these fundamental elements is "Planned Maintenance."

This maintenance encompasses periodic maintenance activities carried out within a predetermined schedule to ensure that organizations' assets (machinery, equipment, facilities, etc.) maintain their functions at the highest level and without interruption. This prevents malfunctions and prevents disruptions to production and workflow.

Planned Maintenance Benefits

Planned maintenance encompasses periodic maintenance activities carried out within a predetermined schedule to ensure that organizations' assets maintain their functionality at the highest level and without interruption. This prevents malfunctions and prevents disruptions to production and workflow.

Planned maintenance offers many benefits to institutions. Some of these include:

1. Prevents Malfunctions: A planned maintenance program allows you to anticipate malfunctions and take the necessary precautions. This prevents production and workflow interruptions caused by malfunctions.

For example, a malfunction on a production line in a factory can cause production downtime and significant financial losses. By regularly maintaining this machine through a planned maintenance program, the risk of failure can be prevented in advance and uninterrupted production can be ensured.

2. Increases Productivity: Regular and effective planned maintenance ensures more efficient operation of equipment and facilities. This contributes to increased production capacity and lower costs.

Statistics: According to a study, companies that implement maintenance effectively can achieve up to 10% increase in production capacity and up to 5% reduction in costs.

3. Improves Product Quality: Well-maintained equipment and facilities help produce higher-quality products. This, in turn, contributes to increased customer satisfaction and a company's competitiveness in the market.

4. Improves Safety: Planned maintenance reduces the risk of workplace accidents. Regularly maintained equipment and facilities provide a safer work environment.

Statistics: According to a study, it has been observed that workplace accidents decrease by up to 20% in companies that implement maintenance effectively.

5. Reduces Costs: Planned maintenance provides significant savings to companies by preventing malfunction repair costs and production losses.

Types of Planned Maintenance

Planned maintenance is the process of periodically inspecting and performing necessary maintenance on equipment and facilities before they malfunction. This process can be implemented using a variety of methods. The most common types of planned maintenance are:

Time-Based Maintenance: This method involves performing equipment maintenance at specific intervals (e.g., every month or every year). This method is simple and easy to implement. However, it may not always be the most suitable solution because it doesn't take into account the actual usage of the equipment.

Usage-Based Maintenance: This method involves maintaining equipment based on usage time or production volume. This method is more flexible than time-based maintenance and takes into account actual equipment usage. However, accurate tracking of equipment usage is essential.

Condition-Based Maintenance: In this method, equipment maintenance is performed based on condition monitoring data. Condition monitoring is the process of monitoring and analyzing equipment operating parameters (e.g., vibration, temperature, pressure). This method is the most advanced planned maintenance method and minimizes the likelihood of equipment failure. However, it is more complex and expensive than other methods.

Preventive Maintenance: This method involves a series of activities performed on a predetermined schedule to prevent malfunctions from occurring. Preventive maintenance helps extend equipment life and prevent production losses due to malfunctions.

Predictive Maintenance: This method is designed to predict and prevent failures before they occur. Predictive maintenance uses condition monitoring data and other information to estimate the probability of failures. This method prevents production losses and extends equipment life by ensuring necessary maintenance is performed before equipment failure.

Risk-Based Maintenance: This maintenance method is based on assessing equipment criticality and risk of failure. In risk-based maintenance, critical equipment is given greater priority and maintenance is performed more frequently.

Implementation of Planned Maintenance

To implement planned maintenance effectively, the following steps must be followed:

• Identifying Assets: Identifying the assets to be included in the maintenance program is the first step. This stage considers criteria such as asset criticality, age, and operating conditions.

• Establishing a Maintenance Schedule: Maintenance activities and their frequency are determined for each designated asset. This schedule includes which parts will be inspected, which tests will be performed, and which spare parts will be available.

• Establishing a Maintenance Team: A team responsible for implementing the planned maintenance program is established. This team should consist of technicians with the necessary knowledge and skills.

• Record Keeping: All maintenance activities and observations are recorded. These records are used to develop future maintenance programs and evaluate the past performance of assets.

• Continuous Improvement: The planned maintenance program is continually reviewed and improved. The program is kept current by following new technologies and methods.

Planned maintenance plays a critical role in ensuring operational effectiveness and corporate sustainability. With a well-planned maintenance program, companies can reduce downtime and maintenance costs, extend equipment life, and increase safety and efficiency.

• Training: We provide training to companies and their personnel on the basics of planned maintenance, its different types and application methods.
• Consulting: We help companies develop and implement planned maintenance programs.

As a Lean Model company, we are always ready with our expert team to help companies develop and implement the planned maintenance programs they need.