The Challenge: Generic PM Strategies Start and Stay Suboptimal
At one of Asia Pacific’s largest coal power plants, the PM program strategy was defined at the equipment class level and rarely revisited. All ACW pumps got a 90-day oil check. All bearings were replaced every two years. When the site did revisit the strategy, it required weeks of reliability and maintenance expert time. They would manually pull work history records, old failure reports, and relevant process data. There was so much activation energy required to initiate a PM strategy re-evaluation project that it was always put on the backburner.
The Solution: Dynamic Optimization, Unique to Every Asset
By automatically evaluating existing strategies against current and historical operations and work history data UptimeAI s Maintenance Optimization Agent eliminated this activation energy. The agent mirrors the asset hierarchy to match the existing work management system, then paretos out the assets with highest potential PM & CM cost savings.
For this customer, ACW Pump-1A proved to be ripe for PM optimization. The agent analyzed the full PM and CM history using statistical methods like Crow-AMSAA and Weibull to determine whether failure patterns were wear-out or infant mortality, then generated a ranked set of specific, implementable recommendations four distinct types in a single view:
- Increase frequency where the PM-to-CM ratio was out of sync doing more preventative work to reduce corrective costs that outweigh the PM spend increase.
- Decrease frequency where zero CM events in the window confirmed safe interval extension, recovering maintenance hours without added risk.
- Add new activities where recurring failures had no existing PM to address them auto-drafting the procedure and checkpoints for direct CMMS import.
- Remove time-based tasks entirely where live sensor data confirmed condition-based monitoring was already available, eliminating redundant calendar-driven work.
Approved recommendations were synched live to their CMMS (SAP), without the need for manual entry. The agent also flagged PMs that were regulatory requirements locking them from the optimization.
The Impact: From 1 ACW Pump to a Site-wide PM Strategy Optimization
After Maintenance Optimization Agent identified ~$100k in potential savings across a single ACW pump, the site was eager to see where else they could make a dent in their maintenance expenses. The program was further extended identifying cost savings of nearly $300k
