Predictive maintenance program development
Asset selection, technologies, routes, P-F intervals, and KPIs — designed so the program still runs after the first burst of enthusiasm.
Predictive maintenance program development is for plants that want condition monitoring that lasts — routes people actually run, technologies matched to failure modes, and KPIs that show whether the program is finding problems early or just collecting files.
How a program is designed
We start with asset selection and the failure modes you are trying to detect, then choose technologies and measurement points, set route frequency against a stated P-F interval, and define what happens when a reading is in the alert or alarm band. ISO 17359 is a useful reference for condition-monitoring program design; it is cited here as a standard to work from, not as a claim that the program is “ISO-certified.”
The practice can support vibration, ultrasound, thermal, and power-quality work. Specialized testing is quoted separately from the $1,200 on-site day rate.
What you leave with
- An asset and technology matrix for the agreed scope
- Draft routes and interval assumptions, including the P-F rationale
- A simple set of KPIs and response rules your team can maintain
A Reliability Assessment is often the right first step if you do not yet know which assets deserve a route. For the funding conversation, use the calculator or a business case.
Scoped per job. No retainers, no mystery.
- A conversation, freeYou describe the asset, the pain, and what “fixed” looks like. You get an honest answer on whether the work is a fit and what it takes.
- A scoped proposalDeliverables, timeline, and price in writing before anything starts. You approve the scope, not a blank check.
- The work, with your teamSessions and analysis done alongside your people, so the method stays in the building when the engagement ends.
- Deliverables you can act onA task list, a business case, or an investigation report — in your format, ready to use.
Work can be purchased by purchase order or invoice. A W-9 is available on request. Use the PO / invoice form, or email inquiry@apexreng.com.
Everything you share stays yours. Plant data, failure history, drawings, and production numbers are never disclosed without your express written permission.
Questions that usually come up
Which technologies do you use?
The mix depends on the failure modes you are trying to detect. Common tools include vibration, ultrasound, infrared thermography, oil analysis, and motor electrical testing. The program should start from the modes, not from a cart of instruments.
What is a P-F interval, in this context?
The time (or running hours) between a detectable potential failure and functional failure. Inspection intervals have to be shorter than the P-F interval you are assuming, or the task will miss the warning. See the article on the P-F interval.
How is it priced?
As a fixed-scope program design or a review of an existing route. On-site time is $1,200 per day plus travel. Specialized testing equipment is quoted separately.