PM/PdM Program Strengthening

Industry: Mining

Client Situation

A major mining operation was experiencing low equipment availability across several critical assets. Preventive maintenance was inconsistent, predictive technologies were underutilized, and corrective work was frequently delayed due to poor task clarity and planning accuracy.

Challenges

• PM tasks were not aligned with actual failure modes
• Predictive maintenance (vibration, infrared, lubrication) was inconsistently applied
• Job plans lacked detail, causing variability in execution
• High levels of reactive work were impacting equipment availability
• No structured workflow for PdM findings or follow-up corrective actions

Approach & Methodology

• Conducted a full PM/PdM program audit across critical equipment
• Mapped failure modes to maintenance tasks using RCM principles
• Rebuilt PM job plans with clear steps, tools, parts, and safety requirements
• Implemented condition monitoring routes and standardized reporting
• Trained planners, supervisors, and technicians on updated workflows
• Established KPIs for PM compliance, PdM findings, and corrective action closure

Key Deliverables

• Updated PM library aligned to equipment criticality
• Predictive maintenance routes (vibration, infrared, lubrication)
• Standardized job plans and work instructions
• PM compliance dashboard
• PdM findings workflow integrated into CMMS

Results & Impact

• PM compliance improved from 62% to 91%
• Reactive work reduced by 28%
• Improved equipment availability across critical assets
• PdM findings integrated into planning, reducing repeat failures
• Standardized job plans improved execution consistency
• Clear workflows increased corrective action closure rates