From an RE perspective developing a maintenance strategy is crucial for asset reliability. Many companies over look the value. My first check is to look at how reactive vs. proactive. I also compare existing KPI's with my own investigation. This identifies the existing conditions.
Your comment on data driven requires investigation of maintenance records, how accurate and consistent. Are all assets listed in detail? With complete bill of materials. Is there a CMMS? What is the PM completion percentage? The CMMS is like a filing cabinet; if it's all in order or all not in order determines the amount of work required. Good record keeping is crucial for accurate PMO evaluation. Hopefully there are work order types: breakdown/reactive, corrective, and preventive/predictive. And captured accurate labor hours and materials used on the asset. To ensure a good PMO rebuild, all costs need identified and compared to the existing PM. So looking from a 50k foot level; good procedures and records are necessary and requires discipline. Of which why responded to the MTTR discussion as it is one factor in labor and material capturing. From this short explanation, do any thoughts arise? This is a topic, at least in my mind, from which at least 11 Reliability Engineering Processes can be examined to achieve reliability excellence.
Sr. Reliability Engineer
Original Message:
Sent: 01-10-2026 07:59 PM
From: Luis Valencia Morón
Subject: The Benefits of Preventative Maintenance Optimization
Hi Terry,
In your experience, how do you ensure that Preventive Maintenance Optimization (PMO) initiatives are truly data-driven and not just a rebranding of time-based maintenance?
Specifically, which KPIs or decision criteria do you use to validate that PM tasks, frequencies, and material usage are effectively aligned with actual failure data?
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Luis Valencia Morón
Gerente General
Asset Healt Management E.I.R.L.
Lima
Original Message:
Sent: 01-08-2026 05:18 PM
From: Terry Alexander
Subject: The Benefits of Preventative Maintenance Optimization
Preventive Maintenance Optimization or (PMO) is not only one of the best continuous improvement activities to implement, but also is important because it transforms your routine non-value-added maintenance from a generic expense into a strategic advantage, ensuring that maintenance efforts are as effective and efficient as possible.
By using a data-driven approach & processto focus resources on critical assets and valuable tasks; organizations can significantly reduce costs, improve reliability, and enhance safety.
The data driven approach most importantly includes recording, and using all routine, corrective, and reactive repair activity to understand failure's. Capturing accurate dates of all activities on the asset is crucial and includes knowing all labor and material used on the asset. This information reveals where the failures are occurring.
Comparing this information to what is actually on the current PM can reveal gaps from existing PMs to what needs to be improved. By leveraging data and technology, such as Computerized Maintenance Management Systems (CMMS), organizations can automate scheduling, track performance, and continuously refine their strategy to balance efficiency and reliability for all assets.
Enhanced Operational Efficiency and Cost Savings is a major benefit as: Well-maintained equipment that runs at peak performance, consuming less energy and delivering consistent output quality. PMO helps eliminate unnecessary maintenance tasks, ensuring that maintenance teams focus their time and resources on activities that truly add value.
Significant Cost Savings: can be achieved by addressing small issues before they escalate into major failures, organizations can avoid expensive emergency repairs and associated costs like overtime labor and expedited parts shipping. It is generally accepted that reactive maintenance can cost three to sixteen times more than a planned, preventive approach.
PM Optimization moves beyond traditional time-based maintenance activities' and identifies failures and materials used against the asset; and ensures the correct maintenance procedures, with the correct frequency will be performed, making reliability and longevity a reality.
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Terry Alexander
Sr. Reliability Engineer
Life Cycle Engineering
Charleston SC
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