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| Asset Identification & Prioritization (STEP) | | |
| Asset Count (Total) (NUMBER) | | |
| Asset Count (Critical - High Risk) (NUMBER) | | |
| Asset Count (Critical - Medium Risk) (NUMBER) | | |
| Asset Count (Non-Critical) (NUMBER) | | |
| Risk Assessment Methodology Used (SELECTION options: FMEA, HAZOP, Bowtie Analysis, Other (Specify)) | | |
| Justification for Critical Asset Designation (For Top 5) (TEXT) | | |
| Criteria Used for Asset Prioritization (SELECTION options: Safety, Production Downtime Impact, Repair Cost, Environmental Impact, Regulatory Compliance) | | |
| Asset Register / Inventory List (UPLOAD) | | |
| Date of Last Asset Prioritization Review (DATE) | | |
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| Current PM Program Review (STEP) | | |
| Overall Description of Current PM Program (TEXT) | | |
| Total Number of PM Tasks Scheduled (NUMBER) | | |
| PM Scheduling Method (Time-Based, Meter-Based, etc.) (SELECTION options: Time-Based, Meter-Based, Manufacturer Recommendations, Other (Specify)) | | |
| Types of PM Tasks Currently Performed (Select all that apply) (SELECTION options: Lubrication, Inspection, Cleaning, Calibration, Replacement of Consumables, Testing, Other (Specify)) | | |
| Average Downtime per Equipment Failure (Hours) (NUMBER) | | |
| Method for tracking PM Completion (SELECTION options: CMMS, Spreadsheet, Paper Records, Other (Specify)) | | |
| List equipment with PM frequency exceeding manufacturer recommendations and reason (TEXT) | | |
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| Data Collection & Analysis (STEP) | | |
| Average MTBF (Mean Time Between Failures) for Critical Assets (NUMBER) | | |
| Average MTTR (Mean Time To Repair) for Critical Assets (NUMBER) | | |
| Total Maintenance Costs (Labor + Materials) per Year (NUMBER) | | |
| Summary of Recent Failure Analysis Reports (TEXT) | | |
| Condition Monitoring Technologies Currently Used (e.g., Vibration Analysis, Infrared Thermography) (SELECTION options: Vibration Analysis, Infrared Thermography, Oil Analysis, Ultrasonic Testing, None) | | |
| Date of Last Comprehensive Equipment Performance Review (DATE) | | |
| Data Sources Currently Used for Maintenance Information (SELECTION options: CMMS (Computerized Maintenance Management System), Work Order Records, Equipment Logs, Operator Reports, External Supplier Data) | | |
| Upload Historical Work Order Data (CSV or Excel) (UPLOAD) | | |
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| Task Optimization & Modification (STEP) | | |
| Is the current PM task truly preventative, or mostly reactive? (SELECTION options: Preventative, Reactive, Unsure) | | |
| Current PM Frequency (e.g., days, weeks, months) (NUMBER) | | |
| Recommended PM Frequency (based on analysis) (NUMBER) | | |
| Justification for frequency change (if applicable) (TEXT) | | |
| Does the current PM task require a specialized tool or skill? (SELECTION options: Yes, No, Unsure) | | |
| Which components are inspected during this PM task? (SELECTION options: Lubrication, Filters, Belts/Chains, Electrical Connections, Sensors, Hydraulic Lines, Other (specify in LONG_TEXT)) | | |
| If 'Other' selected for components, please specify: (TEXT) | | |
| Is the current inspection method adequate? (SELECTION options: Yes, No, Unsure) | | |
| Recommendations for improving the PM task: (TEXT) | | |
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| Condition Monitoring Implementation (STEP) | | |
| Identify Initial Equipment for Condition Monitoring (SELECTION options: Critical Equipment with High Failure Rates, Equipment with High Downtime Impact, Equipment with Limited Accessibility, Equipment with Complex Systems) | | |
| Select Condition Monitoring Technologies (SELECTION options: Vibration Analysis, Infrared Thermography, Oil Analysis, Ultrasonic Testing, Motor Current Signature Analysis (MCSA), Pressure Monitoring, Temperature Monitoring) | | |
| Initial Sensor Placement Count (NUMBER) | | |
| Target Implementation Date for Sensors (DATE) | | |
| Justification for Sensor Selection (TEXT) | | |
| Data Collection Frequency (SELECTION options: Continuous, Daily, Weekly, Monthly) | | |
| Equipment Layout/Schematic (UPLOAD) | | |
| Acceptable Threshold for Early Warning (NUMBER) | | |
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| Resource Allocation & Training (STEP) | | |
| Number of Maintenance Technicians Currently Assigned (NUMBER) | | |
| Average Maintenance Technician Skill Level (1-5, 1=Entry, 5=Expert) (NUMBER) | | |
| Current Allocation of Maintenance Technicians by Equipment Type (SELECTION options: Machinery, Electrical, Pneumatics, Hydraulics, Utilities, Other (Specify)) | | |
| Description of Current Training Programs for Maintenance Staff (TEXT) | | |
| What areas of training are needed to improve efficiency and effectiveness? (SELECTION options: PLC Programming, Hydraulic Systems, Electrical Troubleshooting, Predictive Maintenance Technologies, Root Cause Analysis, Other (Specify)) | | |
| Date of Last Maintenance Staff Skills Assessment (DATE) | | |
| Budget Allocation for Maintenance Training (Annual) (NUMBER) | | |
| Notes on resource constraints impacting PM optimization (e.g., staffing shortages, budget limitations) (TEXT) | | |
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| Documentation & Reporting (STEP) | | |
| Summary of Optimization Changes (TEXT) | | |
| Estimated Cost Savings (Annual) (NUMBER) | | |
| Reduction in Downtime (Hours/Year) (NUMBER) | | |
| Reporting Frequency (PM Optimization Review) (SELECTION options: Monthly, Quarterly, Annually) | | |
| Date of Last PM Program Review (DATE) | | |
| Supporting Data (e.g., Failure Analysis Reports) (UPLOAD) | | |
| Key Performance Indicators (KPIs) Tracked (TEXT) | | |
| Document Control Status (SELECTION options: Draft, Approved, Revised) | | |
| Document Version Number (TEXT) | | |
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| Continuous Improvement & Review (STEP) | | |
| Last Review Date (DATE) | | |
| Frequency of Review (in months) (NUMBER) | | |
| Summary of Review Findings (TEXT) | | |
| Areas of PM Program needing further investigation/improvement (SELECTION options: Task Frequency, Task Procedures, Spare Parts Management, Condition Monitoring Techniques, Training Requirements, Documentation Accuracy) | | |
| Action Items Identified during Review (TEXT) | | |
| Target Completion Date for Action Items (DATE) | | |
| Overall PM Program Health (Post-Review) (SELECTION options: Excellent, Good, Fair, Needs Improvement) | | |
| Reviewer Name (TEXT) | | |
| Reviewer Signature (SIGNATURE) | | |
