Risk-based PM Prioritization Worksheet

{ "Title": "Risk-based PM Prioritization Worksheet", "IntroductionHtml": "

This worksheet helps you prioritize PM effort by scoring each asset on consequence and failure frequency so limited maintenance resources focus on the highest production risk. Fill one submission per asset (or per failure mode). Guidance below shows how to compute the risk score and how to map scores to suggested PM cadences. Use the 'Recommended PM cadence' field to capture your judgment or to follow the suggested mapping after calculating the score.

How to score

Risk score = Consequence ↑ x Failure frequency ↑ (numeric values shown in dropdowns). Example: Consequence 4 x Frequency 3 = Risk 12. Use the mapping below to suggest cadence.

Suggested risk -> PM cadence mapping (example)

• Risk 16–25: Critical — Continuous monitoring / daily or weekly inspections; consider redundancy or redesign
• Risk 9–15: High — Monthly to biweekly PM and pre-position critical spares
• Risk 5–8: Medium — Quarterly PM and condition checks
• Risk 2–4: Low — Semi-annual or annual PM; focus on operator checks
• Risk 1: Negligible — No scheduled PM beyond routine inspection

", "SubmitLabel": "Save asset prioritization", "SuccessMessage": "Saved. Repeat for additional assets or export submissions for batch planning.", "DataType": "pm_prioritization_submission", "SchemaVersion": 1, "Fields": [ { "Key": "equipment_name", "FieldType": "text", "Label": "Equipment name / identifier", "HelpText": "Short name or tag (e.g., 'Press #2', 'Conveyor A - Line 1').", "Required": true }, { "Key": "equipment_id", "FieldType": "text", "Label": "Asset ID / tag (optional)", "HelpText": "Plant tag, serial number, CMMS asset ID or barcode. Helpful for later linking to CMMS.", "Required": false }, { "Key": "location", "FieldType": "text", "Label": "Location / area", "HelpText": "Where the equipment is located (plant/line/zone).", "Required": false }, { "Key": "failure_mode", "FieldType": "textarea", "Label": "Primary failure mode / symptom", "HelpText": "Describe the common failure mode this PM is intended to address (e.g., bearing seizure, hydraulic leak, electrical fault).", "Required": false }, { "Key": "consequence", "FieldType": "select", "Label": "Consequence if asset fails", "HelpText": "Select the worst reasonable consequence for the failure in production, safety, quality, environment, or cost terms.", "Required": true, "Options": [ { "Value": "1", "Label": "1 — Negligible: Little or no production impact; no safety or regulatory impact" }, { "Value": "2", "Label": "2 — Minor: Short production loss; minor rework or scrap; limited cost" }, { "Value": "3", "Label": "3 — Moderate: Shift-level loss, customer impact possible, moderate repair cost" }, { "Value": "4", "Label": "4 — Major: Extended downtime, serious quality/customer impact, high repair cost" }, { "Value": "5", "Label": "5 — Catastrophic: Prolonged plant stoppage, safety/regulatory incident, large financial loss" } ] }, { "Key": "failure_frequency", "FieldType": "select", "Label": "Estimated failure frequency (probability)", "HelpText": "Rate how often this failure is expected to occur if not actively mitigated. Use historical data when available.", "Required": true, "Options": [ { "Value": "1", "Label": "1 — Rare: Less than once per year" }, { "Value": "2", "Label": "2 — Occasional: About 1–4 times per year" }, { "Value": "3", "Label": "3 — Regular: Monthly to quarterly" }, { "Value": "4", "Label": "4 — Frequent: Weekly to monthly" }, { "Value": "5", "Label": "5 — Continuous: Daily or continuous occurrence" } ] }, { "Key": "detectability", "FieldType": "scale", "Label": "Detectability (how easily the failure is detected before serious consequence)", "HelpText": "1 = Hard to detect until failure; 5 = Easily detected early by routine checks or sensors.", "Required": false, "Min": 1, "Max": 5 }, { "Key": "risk_score", "FieldType": "number", "Label": "Calculated risk score (Consequence x Frequency)", "HelpText": "Calculate consequence x frequency and enter the numeric result. The form does not calculate automatically. Example: Consequence 4 x Frequency 3 = 12.", "Required": true }, { "Key": "recommended_pm_cadence", "FieldType": "select", "Label": "Recommended PM cadence", "HelpText": "Choose an appropriate cadence. Use the suggested mapping in the guidance to map from Risk score to cadence, then record your chosen cadence here.", "Required": true, "Options": [ { "Value": "continuous_monitoring", "Label": "Continuous monitoring / daily checks / immediate action" }, { "Value": "weekly", "Label": "Weekly" }, { "Value": "biweekly", "Label": "Biweekly" }, { "Value": "monthly", "Label": "Monthly" }, { "Value": "quarterly", "Label": "Quarterly" }, { "Value": "semiannual", "Label": "Semi‑annual" }, { "Value": "annual", "Label": "Annual" }, { "Value": "defer", "Label": "Defer / no scheduled PM (monitor only)" } ] }, { "Key": "recommended_pm_tasks", "FieldType": "textarea", "Label": "Recommended PM tasks (brief)", "HelpText": "Capture the key PM actions to reduce this failure risk (e.g., 'lubricate bearings, check belt tension, replace seal every 6 months'). Keep tasks concise and actionable.", "Required": false }, { "Key": "recommended_spare_parts", "FieldType": "textarea", "Label": "Recommended spare parts / critical spares", "HelpText": "List critical spare parts to hold (part number, qty recommended, lead time note). This helps planning and spare provisioning.", "Required": false }, { "Key": "estimated_downtime_if_failure", "FieldType": "text", "Label": "Estimated downtime if failure occurs", "HelpText": "Short estimate (e.g., '8 hours', '2 shifts', '3 days'). Useful to prioritize impact on scheduling.", "Required": false }, { "Key": "notes", "FieldType": "textarea", "Label": "Notes / rationale", "HelpText": "Any supporting data, references to failure history, CMMS work orders, or decisions used to justify scores and cadence.", "Required": false } ] }