A structured, on-site maintenance and reliability assessment that ends in a prioritized roadmap with the expected downtime, labor, and cost impact of each action. Not a generic maturity score. Not a binder that sits on a shelf.
Most plants know their downtime is too high. Far fewer know what it costs per hour on their constraint assets, which failure modes drive it, or whether the fix is the PM program, the planning process, the parts, the people, or the leadership. Without that, improvement money goes to whatever failed most recently.
A maintenance and reliability assessment answers those questions the way an owner would. It starts with the cost of the problem, follows the work from request to completion, and checks whether the preventive maintenance in the CMMS is the maintenance that actually happens on the floor.
The assessment draws on the same approach that delivered a 20% reduction in maintenance-driven downtime at a Tier 1 automotive plant: a PM program matched to real failure modes, planning and scheduling discipline that puts wrench time ahead of firefighting, and a maintenance team led like the production asset it is.
How work is requested, approved, prioritized, executed, and closed. Where it stalls, where it bypasses the system, and how much of the week is reactive.
Asset criticality ranking, condition monitoring coverage, and whether PM tasks match the failure modes of the assets they cover (RCM / FMEA thinking, not vendor defaults) — and whether scheduled PMs are actually completed.
Job plans, kitting, backlog size and age, schedule compliance, and the real wrench time available to the crew.
Asset hierarchy, failure coding, work-order history, and whether the data can support decisions or only records them.
Critical spares identified and stocked, storeroom discipline, and how often a repair waits on a part.
Crew structure, skills coverage, contractor dependence, overtime patterns, supervisor span of control, and safe-work practice (LOTO).
How the maintenance department is led and measured — MTBF, MTTR, PM and schedule compliance — and how it works with production.
A direct first conversation, critical assets identified, and the cost of downtime estimated with your finance and production data.
On-site review: the floor, the CMMS, the storeroom, the planning process, and interviews from technicians to plant leadership.
Findings tied to downtime, labor, and cost — so the roadmap can be ranked by payoff, not opinion.
A prioritized plan with quick wins, longer-term actions, and the option to have ProjectMAINT lead implementation.
A structured, on-site review of how a plant's maintenance organization works — work management, asset criticality and PM program, planning and scheduling, CMMS data, spares, skills, and leadership — tied to the cost of unplanned downtime and ending in a prioritized improvement roadmap.
A maturity audit scores you against a generic model. This assessment starts with what downtime costs your plant and ranks every recommendation by its expected downtime, labor, and cost impact, so you know what to fix first and what it is worth.
A written findings report, an estimate of the cost of downtime on your critical assets, a prioritized roadmap with quick wins and longer-term actions, and a read-out for plant leadership.
Yes. ProjectMAINT can lead implementation — PM program redesign, planning and scheduling, CMMS cleanup, spares strategy, and team development — or provide interim maintenance leadership while the changes take hold.
Food and beverage, automotive Tier 1, chemical and process, and metals manufacturing. The method transfers to most discrete and process manufacturing environments.
No. The floor, the storeroom, and the people are where the answers are. The assessment is performed on site, with data review before and after the visit.
Capital build, downtime problem, or leadership gap — the first conversation is free and direct. You'll leave it knowing exactly where your risk is.
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