PM Checklist Procedure

Standard preventive maintenance checklist to track equipment condition and ensure optimal asset performance through systematic maintenance procedures.

Pre-Maintenance Preparation

  • Review asset maintenance history and previous PM records for trends and issues.
  • Verify work order details including asset ID, location, and PM type requirements.
  • Gather all required tools, parts, and materials specified in the PM procedure.
  • Obtain and review manufacturer's maintenance specifications and torque values.
  • Check weather conditions and ensure suitable environment for maintenance work.
  • Coordinate with production schedule to minimize operational impact during PM.
  • Ensure adequate lighting and ventilation in the work area for safety.
  • Review safety data sheets for any chemicals or lubricants to be used.
  • Verify availability of replacement parts and consumables before starting work.
  • Document initial asset condition with photographs if significant issues present.

Safety & Isolation Procedures

  • Implement lockout/tagout procedures for all electrical energy sources per company policy.
  • Isolate and depressurize all pneumatic and hydraulic systems safely.
  • Verify zero energy state using appropriate testing equipment and procedures.
  • Install personal lockout devices and tags according to LOTO protocols.
  • Don all required personal protective equipment including safety glasses and gloves.
  • Establish work area boundaries and install safety barriers if needed.
  • Test emergency stop systems and safety interlocks before beginning work.
  • Ensure fire extinguisher and first aid equipment readily accessible.
  • Communicate with adjacent work areas about maintenance activities in progress.
  • Complete safety permit if required for confined space or hot work.

Visual Inspection & Assessment

  • Conduct thorough visual inspection of asset for obvious damage or wear.
  • Check all safety guards and covers for proper installation and condition.
  • Inspect structural components for cracks, corrosion, or deformation signs.
  • Examine all fasteners for tightness and signs of loosening or corrosion.
  • Look for fluid leaks around seals, gaskets, and connection points.
  • Check electrical connections for signs of overheating or corrosion damage.
  • Inspect drive belts and chains for proper tension and wear indicators.
  • Verify proper alignment of coupled components and drive systems.
  • Check lubrication fittings and ports for accessibility and condition.
  • Document all deficiencies found with location details and severity assessment.

Lubrication & Fluid Service

  • Identify all lubrication points using asset lubrication chart and PM schedule.
  • Clean grease fittings and lubrication points before applying new lubricant.
  • Apply specified grade and quantity of grease to all scheduled lubrication points.
  • Check oil levels in gearboxes, motors, and hydraulic reservoirs.
  • Top off oil levels using manufacturer-specified lubricants and viscosity grades.
  • Inspect oil condition for contamination, color changes, or unusual consistency.
  • Replace oil filters according to maintenance schedule or condition assessment.
  • Check coolant levels and concentration using appropriate testing equipment.
  • Service pneumatic system air dryers and moisture separators as required.
  • Record all lubricants used including type, quantity, and application points.

Operational Testing & Calibration

  • Remove lockout devices and restore energy to asset following proper procedures.
  • Perform startup sequence according to manufacturer's operating instructions.
  • Test all control functions including start, stop, and speed control systems.
  • Verify proper operation of safety systems including emergency stops and interlocks.
  • Check operating parameters such as pressure, temperature, and vibration levels.
  • Calibrate instruments and sensors according to manufacturer specifications.
  • Test alarm systems and warning devices for proper operation and settings.
  • Measure and record key performance indicators such as power consumption.
  • Run asset through full operational cycle to verify proper function.
  • Document any performance deviations from normal operating parameters.

Documentation & Completion

  • Complete all PM checklist items with accurate status and condition notes.
  • Record all meter readings, measurements, and test results in maintenance system.
  • Document parts used including part numbers, quantities, and supplier information.
  • Update asset maintenance history with completed work and findings.
  • Schedule follow-up work orders for any deficiencies requiring corrective action.
  • Calculate and update next PM due date based on calendar or operating hours.
  • Submit completed work order for supervisor review and approval.
  • Return unused parts and materials to inventory with proper documentation.
  • Clean and return all tools to designated storage locations.
  • Communicate asset status to production team with any operational restrictions.

Quality Assurance & Handover

  • Conduct final inspection to ensure all PM tasks completed satisfactorily.
  • Verify all safety guards and covers properly reinstalled and secured.
  • Confirm asset is clean and housekeeping standards met in work area.
  • Test asset one final time to ensure proper operation before handover.
  • Review completed PM checklist for accuracy and completeness.
  • Obtain supervisor signature or approval on completed work order.
  • Brief production personnel on any changes or precautions needed.
  • Update asset status in CMMS system to "Available" or "In Service".
  • File all completed documentation according to company record keeping procedures.
  • Schedule any recommended improvements or modifications identified during PM.
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