Solution Spotlight: PM Optimization


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


A need for PM Optimization becomes evident when we see common issues arise:

  • You still have too many breakdowns, despite PM efforts

  • Reactional, emotional-driven decisions add layers to PM tasks

  • There are issues with equipment being made available for PM

  • Parts are being replaced based on calendar not on condition

  • Invasive PM’s introducing infant mortality and further downtime


The improvement to these issues lies in PM Optimization —a process designed to overhaul PM tasking so that all waste is removed, gaps are filled, and operational efficiency is realized, freeing up valuable labor hours.

So where do you get started?

In most cases, embarking on a total overhaul of your PM maintenance system can be a daunting task. Predictive Service has designed a PM Optimization Pilot to set the stage for, and serve as an example to, the site for defining a future‐state working model.


The pilot process will serve to accomplish the following:

  • Perform PM Optimization on a mutually agreed upon critical asset

    • Identify a current baselining of existing PMs

    • Provide a working model of the application of all optimization techniques

    • Establish the site’s future‐state approach toward PM

  • Quantify the delta on

    • Task coverage for added reliability

    • Total labor impact

    • Scheduled downtime impact

  • Develop roll‐out strategy


Our PM Optimization process follows a proven approach to identify the right tasks, performed by the

right people, in the most efficient and effective manner possible while driving towards minimal

scheduled downtime. A pilot project will deliver:


  • Preventive maintenance tasks including cleaning, adjusting, inspections, lubrication, and applicable condition based and PdM.

  • List of deficiencies, recommendations on modifications for maintainability / accessibility, visual workplace and center lining.

  • Operator care report on tasks meeting agreed upon predefined criteria

  • Development of a single task Single Point Lesson for reference (TPM design and roll‐out falls outside the scope of Baselining activities)

  • PM tasking report

  • PM Sorts by frequency/craft/required equipment status

  • Impact summary report capturing labor, scheduled downtime, and parts impact.

  • Task modification report showing all changes made from original to optimized PM


At Predictive Service, our primary goal is to achieve an increase in the overall reliability in processes while dramatically reducing scheduled downtime, parts and labor and overall risks associated with operating and maintaining capital assets.


Average result compared to existing PM

  • 40% reduction in PM labor hours

  • 35% reduction in scheduled downtime

  • 50% increase in PM coverage


These results further lead to business benefits including:


Increased process reliability:

  • Process Availability – manufacturing assets operating reliably to meet production schedules

  • Throughput – process output rates to design expectations and production requirements

  • Quality – specifications met and scrap eliminated due to poor reliability


Reduced cost and risk:

  • Decreased maintenance and repair costs

  • Decrease in lost production

  • Reduced safety and compliance risks

  • Reduction in potential environmental risks