The Power of Precision: Unlocking Asset Reliability Through PM Optimization
The Problem
This manufacturer was struggling with significant inefficiencies in their preventive maintenance (PM) processes due to incomplete and inconsistent master data in their SAP system. Some assets lacked PM entries entirely; others included only vague titles with no defined tasks, leading to inconsistent practices and over-reliance on mechanic discretion. Identical assets had conflicting procedures, fluids, and task sets, which introduced variability, reduced repeatability, and contributed to avoidable downtime. These gaps in standardization were costing the client both time and resources, diminishing their ability to perform reliable, planned maintenance.
The Solution
Marshall Institute implemented a Preventive Maintenance Optimization (PMO) pilot, initially focused on five critical assets. Working closely with the client, we defined a strategy to enhance the PMs and Bills of Materials (BOMs) by identifying gaps, inefficiencies, and historical usage of parts and materials.
We introduced the PMO methodology in a two-week process:
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Week 1: Training the team in PMO methods and scoping the project.
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Week 2 onward: Cross-functional workshops involving maintenance, operations, engineering, and quality teams to co-develop optimized PMs.
This collaborative approach led to the development of consistent, task-based PM procedures that included specific frequencies, required tools, materials, and clear acceptance criteria. The result was improved accuracy, consistency, and operational control.
The Client
A global manufacturer in the healthcare and consumer goods sector.
The Project
Preventive maintenance (PM) development and standardization for a critical production line. The initiative began as a focused pilot on five key assets and expanded to address over 100 pieces of equipment across the facility.
Services Leveraged
30-day PM Pilot
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The Outcome
Although the initiative began with a five-asset pilot, the work ultimately expanded to include PM optimization for 106 assets. Each now features:
Clearly Defined, Repeatable Procedures
Each asset now has standardized PM tasks that remove ambiguity and ensure consistent execution.
Documented Frequencies and Step-by-Step Instructions
Maintenance teams follow precise timelines and instructions, improving efficiency and reducing variability.
Standardized Tools, Parts, and Materials Lists
Technicians are equipped with exactly what they need before the job begins, minimizing delays.
Guidelines for Identifying and Responding to Unacceptable Conditions
Clear acceptance criteria and response protocols help prevent small issues from becoming major failures.
Building on This Success
Maintenance personnel now execute PMs with greater clarity and consistency. The organization has significantly reduced downtime caused by both inefficient execution and unexpected breakdowns. Preventive tasks are aligned with equipment history, shop floor insights, and manufacturer recommendations, helping to create a proactive and reliable maintenance culture.