Bloated PM libraries
Hundreds of PMs that duplicate, overlap, or have no link to actual failure modes. Time goes in. Reliability does not come out.
UK reliability consultancy
Recover engineering capacity from the maintenance system you already have.
MaintainIQ analyses CMMS data, identifies wasted PM activity, and rebuilds maintenance logic into fixed-scope, CMMS-ready improvement programmes for UK manufacturing sites.
- Fixed-scope reliability improvement, scoped before work begins.
- Starts with the CMMS data you already have. No new system required.
- Outputs built for implementation, not slide decks.
- Designed for manufacturing sites without dedicated reliability resource.
The problem
Your maintenance system may be creating work without reducing risk.
CMMS libraries grow over years. OEM manuals get copied across the site without challenge. Failure history stays unread. Engineers end up maintaining the system instead of improving the plant.
Poor CMMS structure
Asset hierarchies that do not match how the plant actually runs. Reporting becomes guesswork; audit becomes a scramble.
Reactive engineering pressure
Teams spend their week reacting. There is no quiet time to rationalise PMs, refresh asset criticality, or close the loop on failure data.
The MaintainIQ approach
Diagnose. Rebuild. Sustain.
MaintainIQ works from real CMMS data, asset history, and shop-floor knowledge to identify wasted maintenance effort, expose reliability risk, and rebuild preventive maintenance structures into practical CMMS-ready outputs.
01 · Diagnose
Read the system as it is
CMMS export, PM history, downtime and backlog data. We quantify planned-vs-reactive mix, PM duplication, and asset risk exposure.
02 · Rebuild
Make the maintenance logic match the plant
Dynamic RCM and PM Library Optimisation produce CMMS-ready PM tasks aligned to failure modes, criticality, and runtime reality.
03 · Sustain
Keep the gain after we leave
Light-touch monthly or quarterly review keeps PM logic, CMMS structure, and reliability priorities aligned as plant changes.
What we deliver
A focused service ladder, scoped around the work required.
Every engagement starts from evidence and ends with outputs your team can put into the CMMS the next working day.
CMMS Diagnostic & Improvement Plan
Focused diagnostic that quantifies waste, risk, and recoverable engineering hours within 10 working days.
Diagnostic detail →Dynamic RCM
Reliability-Centred Maintenance run as a focused workshop on critical assets — not a six-month committee process.
How we run it →PM Library Optimisation
Each PM task reviewed, tested against failure data, and rewritten or retired. CMMS-ready, not theoretical.
In our programmes →Reliability Performance Support
Monthly or quarterly review keeping PM logic, CMMS structure, and reliability priorities aligned as plant changes.
Support details →
Illustrative example
Before / after: what PM Library Optimisation usually looks like.
A typical single-site programme can identify hundreds of recoverable engineering hours by removing duplicated, low-value, or poorly aligned PM activity. Numbers below are indicative of a mid-size FMCG line and not a guarantee.
Before
- 412 active PMs across line 3
- ~2,180 PM hours/year on the line
- 41% reactive engineering ratio
- 23 PMs duplicate OEM check sheets
- 7 critical assets with no PM coverage
- No documented criticality model
After
- 248 PMs, each linked to a failure mode
- ~1,570 PM hours/year on the line
- Reactive ratio trending toward 25%
- Duplicate OEM tasks merged or retired
- All critical assets with PM coverage
- Audit-ready criticality model in CMMS