Planned Maintenance

Extend Equipment Life and Eliminate Costly Downtime with Planned Maintenance

Planned Maintenance is a proactive maintenance strategy where maintenance activities are scheduled in advance—based on time, usage, or condition—to prevent equipment breakdowns, optimize performance, and extend asset life.

Planned maintenance works on improving the natural life of equipment by implementing various improvement activities and preventing failures through regular maintenance activities including time based maintenance and condition based maintenance. By eliminating the need for maintenance, planned maintenance minimises maintenance costs too.

With our extensive experience in Planned Maintenance, we help companies design and implement effective maintenance strategies that prevent equipment failures, reduce downtime, and extend asset life.

Our approach ensures maintenance activities are scheduled proactively—based on time, usage, or condition—so your operations stay efficient and reliable. We work closely with your team to embed these practices into daily operations, creating a sustainable foundation for long-term performance.

Why is Planned Maintenance important?

Prevents unplanned downtime

Extends Equipment Life

Enhance Safety

Lower Maintenance costs

Improve Productivity & Quality

Key Steps & Approach for Planned Maintenance Implementation

Support Autonomous Maintenance Teams

Training operators to identify and correct the abnormalities
Participating in autonomous maintenance activities and resolving identified red tag abnormalities.
Developing training material in AM step 4 and conducting relay training.

Understand equipment failures

Understand current equipment condition by collecting data on OEE MTBF, MTTR
Preparation of Equipment Control ledger to track and manage various aspects of equipment maintenance and performance
Equipment Ranking to prioritise maintenance efforts and allocate resources effectively

Reverse deterioration

Root cause analysis to reduce repeat breakdowns
Maintenance team skill development to forecast breakdowns and develop countermeasures
Improvement of operation skills including inspection techniques, set up, and adjustment of equipment

Build Management information system

Implementation of MIS covering Breakdown data management system, Equipment maintenance management system, Equipment budget control system are built to gain insights into frequency reasons of breakdowns and cost of failures & defects
Spare parts management system to minimise downtimes related to unavailability of critical and bottleneck spare and to optimise inventory levels of spare parts

Build periodic maintenance systems

Implementation of Time-Based Maintenance (TBM) schedule for maintenance at fixed, scheduled intervals
Implementation of Condition-Based Maintenance (CBM) based on actual equipment condition rather than fixed timing.
Preparation of key Preventive Maintenance (PM) documents, including lubricant control charts, oil change and replenishment schedules, lubrication classification, and inspection standards.

Build predictive maintenance systems

Anticipate and prevent equipment failures by using data analysis and condition monitoring techniques such as thermography, ultrasonic analysis, vibration analysis
Collection and analysis of real-time data by using technology and various condition monitoring techniques

Our Planned Maintenance Experience and Impact

0 300 +

Planned Maintenance projects implemented

0 + 2500

People trained on Planned Maintenance

0 % -50

Reduction in breakdowns

0 % -30

Reduction in maintenance costs

Key Tools used in implementation of Planned Maintenance

MTBF / MTTR

Root Cause Analysis

Time Based Maintenance

Condition Based Maintenance

Predictive Maintenance

Our Clients Results

Automobile & Automotive

Automotive heavy machine shop reduces chronic CNC breakdowns and stabilises machining reliability through TPM

By running a TPM Planned Maintenance project led by the maintenance team, the plant used data-driven analysis, focused engineering changes and standardised maintenance to bring chronic faults under control resulting in higher OEE and machine reliability.

Logistics and Transportation

Logistics company reduces turnaround time and transport cost through Lean Kaizen

Lean Kaizen enabled the logistics company to convert a high-cost, firefighting operation into a more predictable, efficient and customer-focused business.

Oil and Gas

LPG bottling plant improves carousel reliability, reduces breakdowns and cuts truck changeover time through TPM

With a structured TPM “Machine Care” programme, the LPG plant reduced breakdowns, improved carousel performance and shortened truck changeover times unlocking higher throughput without major capital investment.

Paper Manufacturing

Paper mill boosts OEE and stabilises production through TPM

A structured TPM programme in a paper mill, combined with deep PM analysis, improved Autonomous/Planned Maintenance and standardised shutdown practices, delivered higher OEE, lower downtime and more stable fibre supply to the machines.

Advanced Lean Manufacturing Tools

Connect with our Experts!

With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!