Enterprise Preventive Maintenance & Reliability Program
Data-driven maintenance strategy across a multi-site asset fleet reduced equipment failures by 75% and improved uptime to 99.8%.
The Challenge
A multi-site industrial client was experiencing high and unpredictable maintenance costs across their fleet of thermal oxidizers, boilers, and combustion systems. Maintenance was entirely reactive, with no structured inspection cadence. This resulted in expensive emergency call-outs, unplanned production stoppages, and an inability to forecast capital expenditure for aging assets.
Our Solution
We implemented a comprehensive, data-driven Preventive Maintenance (PM) program across all six facilities. The program included quarterly thermal imaging inspections using FLIR technology, semi-annual burner tuning and combustion analysis, valve timing optimization, and vibration analysis on all critical induced-draft and forced-draft fans. We established a critical spares inventory management system and provided detailed asset health reports after each inspection cycle to support long-term capital planning.
Data-Driven Results
- Reduced equipment failures by 75% within the first 18 months of program implementation.
- Lowered overall annual maintenance spend by 20% by eliminating unplanned emergency call-outs.
- Improved average system uptime to 99.8% across all six facilities.
- Provided the client with a 5-year capital expenditure forecast based on asset health data.
Project Details
- Industry
- Industrial
- Failure Reduction
- 75%
- Maintenance Cost Savings
- 20%
- System Uptime
- 99.8%
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