Physical Assets

PM
Optimization

The PM program you have was built one task at a time over twenty years. Most of it doesn't earn its keep. We separate the work that matters from the work that doesn't — and add what's missing.

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Overview

Less PM. Better Reliability.

The conventional PM program in most plants suffers from three problems at once: tasks that don't connect to a real failure mode, intervals that aren't grounded in any actual data, and missing tasks for the dominant failure modes that cause the unplanned downtime everyone is fighting.

PM Optimization solves all three. Using a streamlined RCM-style methodology, we evaluate each PM against the equipment's actual failure modes, eliminate the non-value tasks, fix the intervals that need fixing, and add condition-based or run-based tasks where time-based ones can't see the failure coming.

What's Usually Wrong

Three Common PM Failure Modes

❌

Non-Value Tasks

Tasks that consume hours but don't detect, prevent, or correct any failure mode. They survive only because nobody questioned them.

⏱

Wrong Intervals

Annual when it should be quarterly. Quarterly when condition monitoring would do the job in real-time. Calendar-based when run-time would be better.

🚫

Missing Tasks

The dominant failure mode for a critical asset has no PM at all — and shows up as unplanned downtime month after month.

Methodology

A Pragmatic, RCM-Lite Approach

Full classical RCM is overkill for most assets. Skipping the analysis entirely is reckless. We use a streamlined approach that gets 90% of the value with 30% of the effort.

Step 1

Asset Criticality & Triage

Rank assets by safety, environmental, production, and quality consequence. Focus the analysis depth where it earns its keep — and run-to-fail what should be run-to-fail.

Step 2

Failure Mode Analysis

For each critical asset, identify how it actually fails, how often, and with what consequence. Use existing failure history, not theory.

Step 3

Task Selection

For each failure mode, select the most cost-effective task: condition-based, time-based, run-based, failure-finding, or redesign. Drop tasks that don't fit any of these.

Step 4

Implement & Sustain

Update the CMMS, retire old PMs, train technicians on new ones, and establish the review cadence that keeps the program alive over time.

Typical Outcomes

See Success Stories →

30^–50%

reduction in PM hours

From eliminating non-value tasks

20^%+

reduction in unplanned downtime

From adding the right tasks

40^%