PREDICTIVE MAINTENANCE (PDM) CHECKLIST

Created by ChecklistGuro (https://checklistguro.com)

--- ASSET IDENTIFICATION & PRIORITIZATION ---
[ ] Asset ID
[ ] Asset Name/Description
[ ] Asset Category (Motor, Pump, Gearbox, Compressor, Bearing, Other)
[ ] Criticality Score (1-5, 1=Lowest, 5=Highest)
[ ] Justification for Criticality Score
[ ] Maintenance Strategy (Initial) (Run-to-Failure, Preventative, Predictive, Reliability-Centered)
[ ] Date of Last Inspection/Assessment
[ ] Estimated Replacement Cost
[ ] Associated Hazards (if any) (Environmental, Safety, Production Downtime, Financial, None)

--- DATA ACQUISITION & INTEGRATION ---
[ ] Data Sources Identified? (Yes, No, In Progress)
[ ] Which data sources are currently integrated? (Vibration Sensors, Temperature Sensors, Pressure Sensors, Oil Analysis Reports, Ultrasonic Testing Data, PLC Data (SCADA), CMMS/EAM System, Historical Maintenance Records)
[ ] Number of connected sensors
[ ] Last Data Integration Validation Date
[ ] Data Integration Challenges
[ ] Data Flow Diagram
[ ] Data Transmission Protocol (Modbus, OPC UA, MQTT, Ethernet/IP, Other)
[ ] Data Security Measures in Place

--- CONDITION MONITORING TECHNIQUES ---
[ ] Selected Condition Monitoring Techniques (Vibration Analysis, Thermography, Oil Analysis, Ultrasonic Testing, Motor Current Signature Analysis (MCSA), Infrared Inspection, Acoustic Emission Testing)
[ ] Vibration Analysis - Frequency Range (Hz)
[ ] Thermography - Camera Resolution (MP)
[ ] Oil Analysis - Sample Volume (mL)
[ ] Last Oil Analysis Date
[ ] Time of Ultrasonic Measurement
[ ] Notes on Condition Monitoring Results
[ ] Upload Thermography Image

--- DATA ANALYSIS & MODELING ---
[ ] Vibration Analysis - RMS Amplitude (mm/s)
[ ] Oil Analysis - Viscosity Index
[ ] Thermography - Max Surface Temperature (Â°C)
[ ] Anomaly Detected (Vibration)? (Yes, No, Unsure)
[ ] Description of Observed Anomalies
[ ] Date of Anomaly Detection
[ ] Model Performance Confidence Level (High, Medium, Low)
[ ] Remaining Useful Life (RUL) Estimate (Units of Operation)
[ ] Upload Spectral Analysis Graph (Vibration)

--- MAINTENANCE PLANNING & SCHEDULING ---
[ ] Predicted Remaining Useful Life (RUL) - Component X (in days)
[ ] Scheduled Maintenance Start Date - Component Y
[ ] Estimated Maintenance Duration - Component Z
[ ] Maintenance Type (Based on PdM Prediction) (Routine Inspection, Lubrication, Parts Replacement, Repair, Other (Specify))
[ ] Detailed Maintenance Procedure Notes
[ ] Required Skills/Personnel (Mechanical, Electrical, Instrumentation, Lubrication Specialist, Welding)
[ ] Supporting Documents (e.g., parts list, diagrams)
[ ] Work Order Priority (Based on PdM) (Critical, High, Medium, Low)

--- REPORTING & COMMUNICATION ---
[ ] Number of PdM Reports Generated Per Month
[ ] Report Distribution Method (Email, CMMS System, Shared Drive, Printed Report)
[ ] Date of Last Report Review with Stakeholders
[ ] Summary of Stakeholder Feedback on Last Report
[ ] Which stakeholders receive the PdM Reports? (Production Manager, Maintenance Supervisor, Engineering Team, Plant Manager)
[ ] Communication Frequency for Critical Findings (Immediately, Daily, Weekly)
[ ] Example of a Typical PdM Report

--- PROGRAM REVIEW & CONTINUOUS IMPROVEMENT ---
[ ] Number of Assets Covered by PdM
[ ] Number of Predicted Failures Avoided (estimated)
[ ] Overall PdM Program Cost Savings (estimated)
[ ] Summary of PdM Program Performance Trends (past review period)
[ ] Areas for Improvement Identified (Data Quality, Sensor Coverage, Algorithm Accuracy, Maintenance Team Training, Integration with CMMS, Other)
[ ] Action Items & Assigned Owners (for addressing identified areas for improvement)
[ ] Date of Next Program Review
[ ] Overall PdM Program Effectiveness (Rating Scale) (Very Poor, Poor, Fair, Good, Excellent)
[ ] Recommendations for future PdM expansion or refinement

--- SAFETY & COMPLIANCE ---
[ ] Safety Training Completion (PdM Personnel) (Completed, In Progress, Not Started)
[ ] Permit to Work Compliance Score (Scale 1-10)
[ ] PPE Usage Verification (Routine Inspection) (Compliant, Minor Deviation, Significant Deviation)
[ ] Last Safety Audit Date
[ ] Record of Near Misses/Safety Incidents related to PdM activities
[ ] Compliance with Environmental Regulations (e.g., waste disposal) (Compliant, Minor Deviation, Significant Deviation)
[ ] Documentation of Hazardous Material Handling Procedures (if applicable)
[ ] Name of designated Safety Officer for PdM

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