PM Optimization

Your PM program may be costing you too much with too little benefit. The goal of PMO is to counteract this by ensuring the RIGHT strategy has produced the RIGHT procedures that are being performed by the RIGHT person at the RIGHT frequency. Effective and efficient PM’s can drastically reduce costly reactive maintenance and substantially increase equipment uptime and capacity.

Many maintenance departments struggle because their PM programs are not effective nor efficient. Common deficiencies include:

  1. Inadequate task descriptions that are too short, poorly worded or incomplete
  2. PM tasks performed too often, incurring unnecessary equipment downtime
  3. PM tasks performed too late, allowing failures to occur
  4. PM tasks adding no value and unnecessarily utilizing valuable maintenance resources
  5. PM’s not addressing the true failure mode of the component being inspected
  6. Alternative diagnostic tools and technologies not being considered or not being used
  7. Low PM completion/schedule compliance leading to low PM priority
  8. No accountability for quality PM execution: no follow-up, no audit, no analysis


Did you know?

Up to 30% of PM’s performed may not be adding value!

Many companies in the US spend less than 10% of their maintenance time on PM/PdM activity, while World Class companies spend greater than 40%.

The average “wrench time” of a predominantly reactive maintenance environment is ~25%.

Moving from 25% wrench time to 40% (with a crew of 20 maintenance employees working 40 hours per week) adds 120 hours of value added maintenance time per week with no additional cost!

Reactive maintenance is up to 5 times more costly than proactive maintenance

Next Steps 

Marshall Institute’s industry-experienced coaches are ready to support individuals, teams, and organizations to meet performance goals. Please contact us to inquire about partnering with Marshall Institute to improve Maintenance and Reliability within your organization.

Let’s Get Started.

4-Day PM Optimization Workshop

Marshall Institute’s PM Optimization process provides a proven, structured, RCM-based tool that is used to eliminate or reduce the consequence of failure by:

•  Rationalizing and improving existing PM’s

• Creating PM strategies to mitigate known failures currently not addressed by PM During this 4-day workshop typically targeting a critical asset or bad actor, Marshall Institute will lead your maintenance team through the execution of the PMO process.


We will:

• Review equipment, drawings, manuals, system P&ID, photos, etc.
• Group and review selected PM tasks
• Analyze known or probable failure modes
• Evaluate consequences of each failure mode
• Determine technically feasible and economical maintenance strategies (Condition Based, Time Based Replacement, or Run-To-Failure)
• Develop maintenance tasks including relevant safety precautions, proper tooling, frequency, duration, and pass/fail criteria for each task