Free Maintenance & Reliability tools
85 templates, calculators, worksheets and reference tables. Each runs in your browser and exports to PDF, Excel, Word or CSV.
Templates and forms
TPM Autonomous Maintenance CIL Standard Template
A fill-in operator standard for daily clean, inspect and lubricate tasks on one machine, with frequency, time and pass criteria.
TPM Autonomous Maintenance Standard Template
Generate a one-page operator standard for cleaning, inspecting and lubricating a machine, with limits and escalation.
Maintenance Work Order Template
Fill-in maintenance work order form covering request, safety, tasks, parts, completion data and sign-offs, with PDF and Word export.
Maintenance Shift Handover Log Template
Fill in a one-page maintenance handover between shifts: open jobs, machines down, locked-out equipment, parts on order and safety notes.
Maintenance Job Plan Template
Write a repeatable job plan with steps, craft hours, parts, tools, permits and acceptance checks, ready to attach to a PM or work order.
Equipment Installation and Commissioning Report Template
Document installation checks, run tests, punch list and acceptance for new or relocated equipment before it is handed to production.
Equipment Failure Investigation Report Template
A structured report for investigating an equipment breakdown: what failed, evidence, root causes, corrective actions and sign-off.
Equipment Failure Investigation (RCFA) Report Template
A fill-in report for a significant equipment failure covering impact, timeline, cause analysis, corrective actions and sign-off, ready to export.
Condition Monitoring Route Template
Generate a route sheet that lists assets, measurement points, techniques, alarm limits and sign off so a technician can walk it and record readings.
Vibration Analysis Field Report Template
A fill-in vibration analysis report: asset, route data, spectrum findings, diagnosis, severity and recommended work order. Exports to PDF or Word.
Infrared Thermography Inspection Report Template
A fill-in thermography report covering equipment, camera settings, hotspot temperatures, delta T, severity and recommended repair. Exports to PDF or Word.
Failed Component Teardown Inspection Report Template
A fill-in report for post-failure teardown: what was found, failure mode, probable cause, whether the condition monitoring warning was correct and what changes.
Predictive Maintenance Alert Work Request Template
A document template that turns a vibration, thermography or oil analysis finding into a plannable maintenance work request.
Condition Monitoring Finding and Recommendation Report Template
A one-page report your analyst can send to the planner: what was measured, what it means, how urgent it is and what to do.
Mold Repair Work Order Template
A fill-in work order that records why a mold was pulled, what was repaired and what was verified before it returned to production.
Pressure Relief Valve Set Pressure Test Record Template
Document PSV bench testing: set pressure, cold differential test pressure, seat tightness, adjustments and as-found versus as-left condition.
Worksheets
MTBF and MTTR Worksheet
Track failures, operating hours and repair hours per asset and calculate MTBF, MTTR and availability for each row and for the fleet.
Preventive Maintenance Schedule Template
Editable PM schedule worksheet that turns task intervals and durations into annual runs, annual hours and technician load.
Spare Parts Criticality Scoring Worksheet
Score each spare by consequence of failure, likelihood, lead time and sourcing risk to decide what to stock on site.
Reliability Centered Maintenance (RCM) Worksheet
Editable RCM and FMEA style worksheet that links functions, failure modes and effects to a risk rating and a task selection.
Lubrication Route and Schedule Worksheet
Build a lubrication schedule by point: lubricant, method, grams per shot, shots and frequency, with annual consumption calculated per row.
Planned Shutdown Task Schedule Worksheet
Plan a shutdown task by task with crew, start hour and duration, and see total labor hours, cost and the finish hour of the last task.
Maintenance Technician Skills Matrix Worksheet
Rate technicians on mechanical, electrical, PLC, hydraulics, welding and lubrication skills and find coverage gaps by shift and by skill.
Maintenance Job Plan Labor and Cost Estimate Worksheet
Build a task-level job plan with crew size, hours, rates and parts, and export total man-hours and cost to Excel.
Lubrication Schedule Worksheet
Build a lubrication schedule with points, lubricant, method, quantity and interval, and see annual lubricant consumption per line and in total.
Oil Analysis Sample Log Worksheet
An editable log for oil samples with viscosity change calculated per row, water and iron readings, and an action column. Exports to Excel.
Ultrasonic Bearing Readings Log Worksheet
An editable route log for ultrasound readings. Enter baseline and current dB, get rise over baseline per row and record the lubrication or inspection action.
Condition Monitoring Alarm Limits Register Worksheet
An editable register of baselines, alert and alarm limits by asset and parameter, with percent of alarm calculated from the latest reading.
Motor Insulation Resistance Test Log Worksheet
An editable megger test log that calculates dielectric absorption ratio, polarization index and insulation resistance corrected to 40C.
Condition Monitoring Alarm Limit Worksheet (Statistical Baseline)
Editable worksheet that sets alert (mean + 2 sigma) and alarm (mean + 3 sigma) limits per asset and measurement.
Press Brake Tooling Inventory Log Worksheet
Track punches and dies with ID, V opening, angle, length, rated load per meter, location and last inspection date.
Fusion Splicer Maintenance and Electrode Log
Track each fusion splicer's arc count, electrode replacement, cleaning and service so you act before splice quality drops.
GMP Equipment Use and Cleaning Log Template
An editable equipment log that tracks product, batch, operation, cleaning, verification and the clean hold time left for each use.
Pressure Relief Device Inspection Register Worksheet
An editable register of relief valves and rupture discs with set pressure versus MAWP, test dates and status, exportable to Excel.
Customer-Owned Tooling PM Log Worksheet
Log shots or hits against the preventive maintenance interval for each mold, die or fixture and see how much of the interval is used.
Flange Bolt-Up Torque Sequence Log Worksheet
Log each flanged joint with target torque and calculated pass values at 30, 60 and 100 percent. Edit rows and export to Excel.
Calculators and simulators
Inherent vs Operational Availability Calculator (MTBF, MTTR)
Calculate inherent and operational availability from MTBF, MTTR and logistics delay, with yearly failures, downtime hours and an MTTR sweep chart.
Maintenance Backlog Calculator (Weeks of Work and Crew Size)
Turn backlog hours into weeks of work, estimate the time to clear it and find the crew size that holds it stable.
PM Compliance and Schedule Compliance Calculator
Calculate PM compliance, completion rate, overdue tasks, hours variance and the share of effort spent on preventive work.
Maintenance Cost per Unit Produced Calculator
Calculate maintenance cost per unit produced, as a percent of replacement asset value, with and without the cost of lost production.
Bearing Grease Quantity Calculator
Estimate regrease quantity per bearing, grease gun shots, and annual grease use, cartridges and cost for any number of bearings.
Maintenance Crew Size Calculator
Work out how many maintenance technicians you need from monthly workload, wrench time, absence and a target to clear the backlog.
Optimal PM Interval Calculator (Weibull Cost Model)
Compute the PM interval that minimizes cost per operating hour for a wearing-out component, and see what your current interval costs you each year.
Maintenance Crew Size Calculator
Turn weekly maintenance workload into a required headcount, using real productive hours per technician after absence and wrench time.
P-F Interval Inspection Frequency Calculator
Work out how often to inspect so you catch a potential failure before it becomes a functional failure, and what each inspection interval costs.
Reactive vs Planned Maintenance Cost Calculator
Quantify how much extra your reactive work costs and what a lower reactive percentage would save each year.
Maintenance Contractor vs In-House Technician Cost Calculator
Compare the annual cost of covering a workload with employees against a contractor, and find the break-even hours.
Critical Spare Stockout Risk Calculator (Poisson)
Decide how many slow-moving critical spares to hold by comparing stockout risk and cost for each stock level.
Maintenance Technician Staffing Calculator
Work out how many full-time maintenance technicians your workload needs, using annual hands-on hours, backlog reduction and wrench time.
Bearing Defect Frequency Calculator (BPFO, BPFI, BSF, FTF)
Enter shaft speed, ball count, ball and pitch diameter and contact angle to get the four bearing fault frequencies in Hz for spectrum analysis.
Motor Efficiency and Energy Cost Calculator
Estimate what an induction motor costs to run per year, how much is lost as heat, and how fast a premium efficiency motor pays back.
Compressed Air Leak Cost Calculator
Convert a leak rate into lost compressor energy and annual cost, then test the payback of an ultrasonic leak survey and repair.
P-F Interval Calculator
Use the P-F interval to set condition-based inspection frequency, check the chance of catching a failure and see if you have time to react.
Bearing L10 Life Calculator
Compute L10 life in million revolutions and hours for ball or roller bearings, apply a reliability factor, and see how life falls as load rises.
Bearing L10 Life Calculator (ISO 281)
Basic and adjusted rating life of ball and roller bearings from C, P and rpm, with a load sweep chart.
Vibration Velocity, Acceleration and Displacement Converter
Convert a single-frequency vibration reading between velocity, acceleration and displacement, with a frequency sweep chart.
Bearing Grease Quantity and Annual Cost Calculator
Relubrication quantity by the G = 0.005 x D x B rule, plus yearly grease consumption and spend across a bearing population.
Motor Winding Insulation Life vs Temperature Calculator
Thermal margin and expected insulation life of a motor from class, ambient, rise and hot spot allowance, with an ambient sweep.
VFD Pump Affinity Law Energy Savings Calculator
Power at reduced speed by the cube law versus throttled constant speed operation, with annual savings and payback.
Preventive Replacement Interval Cost Calculator (Weibull)
Compare cost per hour of age-based replacement against run to failure for a wear-out component, with an interval sweep chart.
Hydraulic Cylinder Force and Flow Calculator
Calculate push and pull force from bore, rod and pressure in bar, convert to kN and lbf, and size the oil flow needed for a given cylinder speed.
Motor Torque and Speed to Power and Energy Cost Calculator
Convert shaft torque in Nm and speed in RPM to kW, hp and lb-ft, then estimate electrical input power and yearly energy cost for a motor-driven machine.
Component Removal Rate, MTBUR and NFF Cost Calculator
Compute MTBUR, MTBF, removal rate per 1,000 hours and the annual cost of no-fault-found removals from fleet hours and removal counts.
MRO Hangar Check Capacity Calculator
Find how many base maintenance checks a hangar can complete per year given bays, technicians, productivity and target turn time, and see which one limits you.
Maintenance Check Interval Escalation Savings Calculator
Estimate annual and multi-year savings from extending a base check interval: checks avoided, direct cost saved and aircraft days regained.
Chemical Transfer Pump Power and Energy Cost Calculator
Size pump power from flow, differential head and fluid density, then estimate yearly electricity cost.
Machine Availability Guarantee MTBF MTTR Calculator
Compute inherent and operational availability from MTBF, MTTR, parts wait and planned maintenance, and compare it with a contractual guarantee.
Flange Bolt Torque Calculator (Preload and Nut Factor)
Compute bolt stress area, target preload and tightening torque from bolt size, pitch, yield strength, percent of yield and nut factor.
Remaining Life and Corrosion Rate Calculator
Convert two thickness readings into a corrosion rate, the remaining life to minimum thickness and a half-life inspection interval.
Reference tables
TPM Pillars and Autonomous Maintenance 7 Steps Reference
The eight TPM pillars and the seven autonomous maintenance steps in one searchable table, with purpose, typical outputs and common pitfalls.
ISO 14224 Failure Mode Codes Reference
A searchable table of the three-letter failure mode codes used in ISO 14224 reliability data collection, with plain-English meanings and typical equipment.
ISO VG Lubricant Viscosity Grades Reference
A lookup table of ISO 3448 viscosity grades, showing the kinematic viscosity midpoint and the allowed minimum and maximum at 40 C in cSt.
Vibration Severity ISO 10816 Zone Reference
Look up the A/B, B/C and C/D zone boundaries in mm/s RMS for ISO 10816 machine classes and groups, with a plain-language note on what each zone means.
Vibration Fault Signature Diagnosis Reference
A searchable lookup of what each common machine fault looks like in a vibration spectrum, with dominant frequency, direction and the first check to make.
ISO 4406 Oil Cleanliness Code Reference
Look up the particle count range behind each ISO 4406 range number, so you can read and set hydraulic and lube oil cleanliness targets.
Infrared Thermography Severity and Emissivity Reference
Quick lookup of temperature rise priorities for electrical thermography and typical emissivity values for common surfaces.
Code and query generators
CMMS Overdue PM Work Orders SQL Generator
Fill in your table and column names and get a ready SQL query for overdue PM work orders and a PM compliance summary, in SQL Server and PostgreSQL syntax.
MTBF and MTTR From a Failure Log Python Script Generator
Name the columns in your CSV export and get a pandas script that works out MTBF, MTTR, failure count and availability for each asset.
Condition Monitoring Alarm SQL Query Generator
Fill in your table and column names and get SQL that finds sensor readings over limits and flags assets with no open work order.
Condition Monitoring Trend and Time-to-Alarm Python Script Generator
Get a standard-library Python script that fits a trend to recent sensor readings and estimates how many days remain before an alarm limit is crossed.
Checklists
Condition Monitoring Program Readiness Checklist
A practical checklist for starting or auditing a condition monitoring program, from asset selection to closing the loop in the work order system.
Injection Mold Maintenance Checklist
A practical preventive maintenance checklist for injection molds, from daily checks at the press to full overhaul and storage.
Assessments
Maintenance and Reliability Maturity Assessment
Ten questions covering work management, preventive maintenance, spares, data and root cause practice, with a score and practical next steps.
Condition Monitoring Program Readiness Assessment
Answer 10 questions about assets, data, skills and follow through to see how ready your plant is for a predictive maintenance program.
Predictive Maintenance Data Readiness Assessment
Ten questions that show whether your asset data, failure history and sensor coverage can support predictive maintenance, and what to fix first.