PM Optimization Services
Do you perform too much PM maintenance, not enough or are you not achieving the desired results? Predictive Service’s PM Optimization removes waste and ensures all PM tasks add value and addresses known failure modes.
- Transforming Preventive Maintenance Strategies for Greater Effectiveness
Studies have shown very little relationship between calendar-based PM maintenance and improved reliability. In fact, PM maintenance can often be detrimental to reliability if your PMs do not provide clear, precise instructions or executed at the wrong frequency. Industry-wide, we still see high levels of reactive maintenance from unplanned downtime events, even with high levels of PM maintenance meant to control or minimize those events.
When you evaluate your existing PM strategy, do you believe your program is effective or do you feel changes need to be made? Limitations can be found throughout the entire program, stemming from how the PM actions were created, copied, scheduled and subjectively executed. A need for PM Optimization becomes evident when we see common issues arise:
- You still have too many breakdowns, despite PM efforts
- Emotion-driven decisions add complication to PM execution
- There are issues with equipment being made available for PM
- Machines are being deactivated too often for PM, resulting in downtime
- Parts are being swapped out that are still useful
- New problems emerge after PM actions are taken
What can be done about this troublesome trend? The answer lies in PM Optimization —a process designed to overhaul PM operations so that all waste is removed, gaps are filled, and operational efficiency is realized, freeing up valuable labor hours.
Predictive Service’s PM Optimization program has been shown to deliver tremendous results:
- 15 percent elimination of tasks that provide no value
- 80 percent increase in objective, data-driven PM actions
- 40 percent reduction of maintenance labor hours
- 50 percent increase in required PM task coverage
- 35 percent reduction in scheduled downtime hours
How We Can Help
Preventing failure at a component level, Predictive Service’s robust process eliminates the unnecessary, optimizing current activities and supplementing tasks to address gaps. The result is a PM program tailored to best practices, including elevating typical fixed time based tasks to conditioned-based, operator care or predictive maintenance tasks. Our comprehensive approach to PM Optimization expands beyond task optimization to encompass a program focused on overall system change. Predictive Service’s PM Optimization solution relies on enhanced, proven tools and training that follows a model for continuous improvement.
Predictive Service has developed a four-step process for lasting, effective PM operations:
Step 1: Define a business case for PM, bringing awareness and focus to issues
- PM Optimization awareness workshop
Step 2: Engage in quantitative exercises to measure your exact progress
- PM Optimization initial modeling
- Strategy development
- Component library development
- Maintenance and reliability metrics workshop
Step 3: Begin tactical implementation with tools and training
- Turnkey or partnership-based rollout and delivery of PM Optimization activities across asset classes
Step 4: Adoption of systems and tools to ensure sustainability and continued growth
- Root cause failure analysis (RCFA)
- Failure mode and effect analysis (FMEA)
- Maintenance, repair and operations (MRO) Optimization
- Value stream mapping
- e-Learning training services for continual education