News & Research: Client Successes

Case Study: Preventive (PM) and Predictive (PdM) Maintenance Optimization

ScottMadden worked with a maintenance services provider to establish a comprehensive, cost effective, and standardized program for performing maintenance activities.

• Facility Preventive and Predictive Maintenance (PM/PdM) tasks had not been reviewed and updated in several years to reflect industry best practices or jurisdictional code requirements
• While PM/PdM tasks were performed by the client, the PM/PdM programs were owned by the client's customer
• PM/PdM tasks were not standardized across the facility for assets of similar design and operating duty
• Compliance with equipment nomenclature standards was lax, preventing accurate determination of asset condition and maintenance costs
• Total cost of the PM/PdM program was unknown in terms of mobilization, demobilization, and actual task performance
• Previous initiatives to meet these objectives had been attempted; however, these efforts were done without the establishment of a solid, repeatable process and were not supported by detailed, credible data.  This made it difficult for the client to gain the required support and approval from its customer
• Maintenance data within PassPort were improperly maintained, preventing accurate and complete review of maintenance history, costs, and equipment status

• Created a project team comprised of key client and customer stakeholders to address and resolve concerns and issues
• Updated and standardized equipment listings within the maintenance database
• Developed comprehensive, baseline PM and PdM tasks that reflect codes, standards, and best practices
• Customized PM and PdM tasks within specific facilities based on equipment application and duty cycle
• Established detailed task cost estimates ,which included adjustments for mobilization, demobilization, and work environmental factors
• Optimized the execution of PM activities through schedule bundling and routing

• Decreased PM/PdM maintenance program labor and material costs
• Improved cost compliance with PM/PdM program and understanding of the actual cost of the program
• Increased system and equipment availability and reliability
• Formalized documentation of maintenance tasks
• Increased schedule fidelity for resource allocation
• Optimized resource level-loaded PM/PdM schedule