FMEA and Preventive Maintenance Optimization (PMO) Close Maintenance Gaps


Failure modes identified and mitigated


Existing maintenance tasks organized

Industry: Chemical Processing


Improve critical rotating asset reliability to ensure supply, eliminate batch rework, avoid negative operational cost, and eliminate related foreign matter.


Allied Reliability’s best practices and tools were used to identify and close gaps in the existing Preventive Maintenance (PM) / Condition-based Maintenance (CBM) program.

To begin, Allied assisted the client in conducting a data review including the following:

  • Review Item Discrepancies (RID)
  • Quality Assurance Review (QAR) / Foreign Material
  • Equipment Downtime
  • CMMS corrective work order history

The team then worked to implement a consistent parent-child mapping of equipment and components following the ISO 14224 taxonomy. Next, leveraging Allied tools, the client's existing equipment maintenance strategy was reviewed and enhanced.

The team discovered that 161 of the 489 (33%) failure modes identified were not addressed in the existing strategy. Further analysis revealed that 235 of the 519 (45%) PM tasks did not address specific failure modes and did not minimize variability of execution prior to optimization.

Finally, with the updated information and plan in place, Allied recommended CBM technologies to address the applicable failure modes including vibration and infrared thermography.