Risk-based preventive maintenance (PM) plan template

{"Title":"Risk-based PM Plan Template","IntroductionHtml":"

Purpose

Use this template to convert ad‑hoc checks into scheduled preventive maintenance that targets real failure modes and downtime drivers. The goal is to protect critical assets while avoiding low‑value over‑servicing. Capture the PM in a way that can be fed into your CMMS or planning process.

How to use

• Identify the asset and its criticality relative to production, safety, quality, and environment.
• List the failure modes you are addressing and why those matter.
• Define a concise task description and clear acceptance criteria so work can be checked and recorded consistently.
• Choose a frequency justified by data, condition, usage, or failure interval; avoid calendarizing without rationale.
• Estimate duration, tools, and spare parts so planning and stores can load the work order correctly.
• Give each PM an owner and a review interval so PMs stay accurate and relevant.

Note: This tool captures fields that make a PM actionable. For fleet‑level prioritization, combine criticality and failure likelihood into a risk score in your CMMS or analytics tool. Do not use this form as a substitute for engineering or safety reviews.

","SubmitLabel":"Save PM Plan","SuccessMessage":"PM plan saved. You can export or copy fields into your CMMS or planning system.","DataType":"PMPlanTemplate","SchemaVersion":1,"Fields":[{"Key":"assetId","Label":"Asset ID","FieldType":"text","HelpText":"Unique identifier used in your CMMS (e.g., TAG‑123).","Required":true},{"Key":"assetName","Label":"Asset name","FieldType":"text","HelpText":"Common name (e.g., Packaging Line 2 – Conveyor A).","Required":true},{"Key":"location","Label":"Location / Area","FieldType":"text","HelpText":"Plant, area, or cell where the asset is located."},{"Key":"assetCriticality","Label":"Asset criticality","FieldType":"select","HelpText":"Impact of asset failure on safety, quality, delivery or cost. Use your site scale.","Required":true,"Options":[{"Value":"critical","Label":"Critical (stops production / safety risk)"},{"Value":"high","Label":"High (major impact on output or cost)"},{"Value":"medium","Label":"Medium (noticeable impact)"},{"Value":"low","Label":"Low (limited impact)"}]},{"Key":"failureModes","Label":"Failure modes addressed","FieldType":"textarea","HelpText":"List the specific failure modes this PM is intended to prevent or detect (e.g., bearing wear, belt misalignment, seal leakage). Include symptoms and typical consequences.","Required":true},{"Key":"primaryFailureMode","Label":"Primary failure mode","FieldType":"text","HelpText":"If one failure mode is the main driver, name it here."},{"Key":"impactOfFailure","Label":"Impact of failure (brief)","FieldType":"textarea","HelpText":"Describe consequences: downtime minutes, scrap, safety, environmental, or customer effect."},{"Key":"taskDescription","Label":"PM task description","FieldType":"textarea","HelpText":"A short, actionable description of the task operators or technicians will perform (e.g., inspect bearing housing, measure play, apply grease to point A). Write steps in standard work format if possible.","Required":true},{"Key":"taskSteps","Label":"Recommended task steps (optional)","FieldType":"textarea","HelpText":"Step‑by‑step steps technicians should follow. Keep them concise and testable."},{"Key":"frequencyType","Label":"Frequency type","FieldType":"radio","HelpText":"Choose the best basis for scheduling the PM.","Required":true,"Options":[{"Value":"calendar","Label":"Calendar (e.g., monthly)"},{"Value":"usage","Label":"Usage / runtime (e.g., hours, cycles)"},{"Value":"condition","Label":"Condition‑based (e.g., vibration, oil analysis)"},{"Value":"event","Label":"Event‑driven (e.g., start of season)"},{"Value":"other","Label":"Other"}]},{"Key":"frequencyValue","Label":"Frequency value","FieldType":"text","HelpText":"Specify the frequency (e.g., 30 days; 500 operating hours; inspect weekly). If condition‑based, state the sensor or threshold."},{"Key":"frequencyRationale","Label":"Frequency rationale","FieldType":"textarea","HelpText":"Short justification: based on failure history, OEM recommendation, FMEA, condition thresholds, or observed degradation."},{"Key":"estimatedDurationMinutes","Label":"Estimated duration (minutes)","FieldType":"number","HelpText":"Typical time to complete one PM instance (minutes). Include setup and verification time.","Required":true},{"Key":"estimatedLaborHours","Label":"Estimated labor (hours)","FieldType":"number","HelpText":"Total technician hours (decimal). Use this for planning and labor planning."},{"Key":"requiredTools","Label":"Required tools","FieldType":"textarea","HelpText":"Tools or gauges needed (e.g., torque wrench, vibration meter)."},{"Key":"spareParts","Label":"Spare parts / consumables","FieldType":"textarea","HelpText":"Part numbers, quantities, and suggested stock levels. Helps material reservation and kitting."},{"Key":"acceptanceCriteria","Label":"Acceptance criteria","FieldType":"textarea","HelpText":"Clear pass/fail criteria or measured tolerances (e.g., vibration < 4 mm/s; torque restored to 20 Nm). This makes the PM verifiable.","Required":true},{"Key":"recordFields","Label":"Record fields to capture","FieldType":"textarea","HelpText":"What will the technician record when completing the PM (e.g., torque values, grease applied Y/N, replaced part number, serial)."},{"Key":"linkedWorkOrderTemplate","Label":"Linked work order template ID","FieldType":"text","HelpText":"ID or name of the work order template in your CMMS that this PM should create or reference."},{"Key":"lastPerformedDate","Label":"Last performed date","FieldType":"text","HelpText":"Optional. Use YYYY‑MM‑DD format if available."},{"Key":"reviewInterval","Label":"PM review interval","FieldType":"select","HelpText":"How frequently should this PM be reviewed for effectiveness?","Options":[{"Value":"3m","Label":"Every 3 months"},{"Value":"6m","Label":"Every 6 months"},{"Value":"12m","Label":"Every 12 months"},{"Value":"other","Label":"Other"}]},{"Key":"pmOwner","Label":"PM owner","FieldType":"text","HelpText":"Team or person responsible for accuracy and review (e.g., Reliability Tech, Area Maintenance Lead).","Required":true},{"Key":"riskPriority","Label":"Suggested priority","FieldType":"select","HelpText":"Suggested scheduling priority combining criticality and failure impact; use your site policy to finalize.","Options":[{"Value":"p1","Label":"Priority 1 — Immediate / top"},{"Value":"p2","Label":"Priority 2 — High"},{"Value":"p3","Label":"Priority 3 — Normal"},{"Value":"p4","Label":"Priority 4 — Low"}]},{"Key":"notes","Label":"Notes and references","FieldType":"textarea","HelpText":"Links to OEM manuals, FMEA references, historical downtime records, or condition monitoring data."}]}