Template

Risk-based preventive maintenance (PM) plan template

An interactive PM plan template that links tasks to failure modes, criticality, frequency, estimated duration, spare parts, and acceptance criteria — designed to produce CMMS‑ready PMs that protect critical assets without over‑servicing.

Interactive Tool

Risk-based PM Plan Template

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.

Unique identifier used in your CMMS (e.g., TAG‑123).
Common name (e.g., Packaging Line 2 – Conveyor A).
Plant, area, or cell where the asset is located.
Impact of asset failure on safety, quality, delivery or cost. Use your site scale.
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.
If one failure mode is the main driver, name it here.
Describe consequences: downtime minutes, scrap, safety, environmental, or customer effect.
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.
Step‑by‑step steps technicians should follow. Keep them concise and testable.
Choose the best basis for scheduling the PM.
Specify the frequency (e.g., 30 days; 500 operating hours; inspect weekly). If condition‑based, state the sensor or threshold.
Short justification: based on failure history, OEM recommendation, FMEA, condition thresholds, or observed degradation.
Typical time to complete one PM instance (minutes). Include setup and verification time.
Total technician hours (decimal). Use this for planning and labor planning.
Tools or gauges needed (e.g., torque wrench, vibration meter).
Part numbers, quantities, and suggested stock levels. Helps material reservation and kitting.
Clear pass/fail criteria or measured tolerances (e.g., vibration < 4 mm/s; torque restored to 20 Nm). This makes the PM verifiable.
What will the technician record when completing the PM (e.g., torque values, grease applied Y/N, replaced part number, serial).
ID or name of the work order template in your CMMS that this PM should create or reference.
Optional. Use YYYY‑MM‑DD format if available.
How frequently should this PM be reviewed for effectiveness?
Team or person responsible for accuracy and review (e.g., Reliability Tech, Area Maintenance Lead).
Suggested scheduling priority combining criticality and failure impact; use your site policy to finalize.
Links to OEM manuals, FMEA references, historical downtime records, or condition monitoring data.
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