Industrial
maintenance,
in depth.
Two decades of experience inside the world's largest factories — the full spectrum of industrial maintenance from a single partner.
The full breadth and depth of maintenance, handled by a single team — built on real factory experience.
44 sub-areas across 6 core disciplines — for every maintenance question.
These six disciplines are usually deployed in combination, not in isolation. A typical Partner-tier engagement begins with a Feasibility Study to set the baseline, then layers in Maintenance Improvement and Productivity & OEE in parallel, while Digital Transformation is introduced once reliability baselines stabilise. Factory & Startup Management and CMMS/EAM may run as standalone engagements or as foundations for longer programmes.
Maintenance Improvement
From reactive firefighting to reliability-centred maintenance (RCM). Preventive-maintenance plans, FMEA and root-cause analysis, planning & scheduling, and spare-parts management — all in one framework. The typical result: significantly fewer unplanned stoppages and a steadily lower cost per unit produced.
Continuous Improvement
Embedded cycle of measure-analyse-improve that compounds small gains into durable performance lifts across maintenance teams.
Reliability-Centred Maintenance
Asset-criticality-driven strategy that focuses intervention where failure has the greatest operational and financial impact.
Planning & Scheduling
Weekly planning-and-scheduling cycle that converts backlog into structured work orders at 90%+ schedule compliance, reducing reactive work.
Maintenance Management
Frameworks defining roles, responsibilities, KPIs, and regular reporting that ensure results are sustained over the long term.
Preventive & Predictive Maintenance
PM plan design and predictive-analytics integration that shift work from breakdown response to scheduled intervention.
Spare Parts Management
Min/max optimisation, obsolescence management, and vendor consolidation that cut inventory carrying cost by 15–30%.
Maintenance Process Development
Documented standard operating procedures for work intake, execution, and close-out, ensuring consistency across sites and shifts.
Organizational Structure Improvement
Redesign of maintenance org charts, spans of control, and skill mixes to match plant size and asset mix.
Failure Mode and Effects Analysis (FMEA)
Systematic failure-mode mapping that converts breakdown history into engineered prevention, typically cutting MTTR by 40–60%.
Root Cause Analysis (RCA)
Structured problem-solving method that identifies underlying failure drivers and engineers them out rather than re-fixing symptoms.
Lifecycle Cost Analysis (LCCA)
Economic evaluation of asset alternatives across the full lifecycle, enabling capex decisions grounded in total cost of ownership.
Shutdown Management
Major-turnaround planning and execution covering critical path, contractor coordination, and cost control during multi-week outages.
Productivity & OEE
We don't just measure OEE — we improve it. We stand up the measurement, define the KPIs, and run targeted projects that eliminate availability, performance, and quality losses.
OEE Measurement System Design
Design of OEE capture at the right granularity — typically per shift, per line, per loss category — to drive action rather than dashboards.
OEE Measurement System Implementation
On-site rollout of OEE data collection, with operator training and shop-floor displays visible directly to operators.
OEE Improvement Projects
Structured initiatives targeting the largest availability, performance, or quality losses identified through OEE measurement.
KPI Package Definition
Establishment of a structured set of indicators with regular tracking across maintenance, production, quality, and safety.
5S Implementation
A foundational workplace culture that makes an orderly, clean, and transparent work environment a daily practice — laying the foundation for improving maintenance and production efficiency.
Design-Out Projects
Engineering interventions that remove recurrent failure modes at the asset level rather than treating the same breakdown repeatedly.
CAPEX Investment Management
Capital-project governance covering scoping, vendor selection, commissioning, and post-project performance verification.
Major Overhaul Project Management
End-to-end project leadership for the overhaul of an individual major asset — from planning through to handover to production.
Overhaul Project Management
End-to-end project leadership for major equipment overhauls, from scope definition through commissioning and handback to operations.
Digital Transformation
We make maintenance visible: systems and IoT sensors take over from paper and manual data entry, and that data comes together into a clear decision-support picture. From reactive break-fix to preventive and then predictive maintenance — all built on the client's existing platform.
Digital Transformation Strategy
Multi-year digitalisation roadmap that prioritises initiatives by business impact, with measurable results at the end of each phase.
Digitalization Project Management
Execution leadership for individual digital initiatives — sensor deployments, dashboard rollouts, or CMMS extensions — with clear ownership and scope control.
ThingWorx Integration & Development
PTC ThingWorx platform build and integration connecting shop-floor machines to enterprise analytics and maintenance workflows.
Sensor & Device Consulting
Selection and deployment advisory for condition-monitoring sensors and edge devices matched to specific asset types and failure modes.
PowerBI Dashboard Development
Custom Microsoft PowerBI dashboards that turn CMMS and sensor data into decision-grade visibility for maintenance and production leadership.
Factory & Greenfield Project Management
We build the maintenance function before start-up, not after. Organisation, preventive-maintenance plans, and CMMS — all in place before the first production cycle. The result is a meaningfully shorter ramp-up to full capacity.
Maintenance Process Setup
Design and documentation of maintenance processes — work intake, planning, execution, close-out — before the first production run.
Maintenance Systems & Tools Implementation
CMMS, mobile work-order tools, and lockout-tagout systems deployed in parallel with equipment installation, not after.
Maintenance Organization Design
Role definitions, shift structures, and reporting lines sized to the asset base and production intensity of the new facility.
Team Skills Development
Phased training that prepares every level of the maintenance and operations organisation — from operators to managers — to apply maintenance processes in their daily work.
Preventive Maintenance (PM) Plan Implementation
Asset-specific PM plans built from OEM recommendations and Propelance reliability experience.
Production Equipment Installation Support
Professional support for production-equipment installation from a maintenance perspective — from installation through commissioning to production start-up.
CMMS & EAM
We work vendor-independently — across IBM Maximo, SAP PM, Hexagon EAM, and other platforms. On new rollouts we work alongside the system-implementation partner; on existing systems we build on the platform already in use — refining its data structure, workflows, and KPIs.
IBM Maximo Solutions
Full-stack Maximo rollout including asset hierarchy, master data, workflow design, and integration with ERP and OT systems.
SAP PM Solutions
SAP Plant Maintenance configuration and customisation, including procurement-process setup and integration with finance and inventory modules.
Hexagon EAM Solutions
Design and optimisation of maintenance solutions built on the Hexagon EAM platform (formerly Infor EAM).
Asset Hierarchy Design
Structured breakdown of plant, area, equipment, and component levels that enables meaningful cost attribution and failure analysis.
Core Business Process Integration
End-to-end connection of CMMS workflows with procurement, inventory, finance, and production scheduling systems.
CMMS User Training & Adoption
Role-based training programmes that prepare users — technicians, planners, and managers — for confident, independent daily use of the system.
Work Order & Scheduling Configuration
Work-order types, priority matrices, and scheduling rules tuned to each site's operational rhythm and asset criticality.
Frequently Asked Questions
What does Propelance do?
We help industrial factories design, implement, and improve how their maintenance function works. Our work spans maintenance strategy, the rollout of reliability-centred operations, and the introduction of CMMS systems and OEE measurement — always on-site in the real factory environment, working alongside the client's team.
What does a CMMS implementation include?
Propelance designs and builds CMMS-based solutions tailored to each client's environment — from system selection through asset-hierarchy design, master-data build, work-order workflow configuration, and integration with connected systems, to user training. We work vendor-independently, with deep experience across IBM Maximo, SAP PM, and Hexagon EAM.
What is the difference between preventive and reliability-centred maintenance?
Preventive maintenance schedules work at fixed intervals regardless of equipment condition. Reliability-centred maintenance (RCM) prioritises interventions by asset criticality and failure mode, using FMEA and root-cause analysis to focus effort where it most reduces unplanned downtime.
How long does a factory assessment take?
A Propelance factory assessment is completed in four to six weeks on average. It combines on-site inspections, structured interviews, and data analysis across eight evaluation areas, and concludes with an executive report setting out prioritised improvement recommendations.
Which industries does Propelance serve?
The fundamentals of maintenance are industry-independent, so Propelance has worked in virtually every sector except nuclear power. Typical industries include electronics, food & beverage, pulp & paper, chemicals, oil & gas, energy, and machinery manufacturing — with active projects across 22 countries since 2007.
Does Propelance deliver independent audits?
Yes — we deliver audits across eight areas: HSE, maintenance organisation, productivity & OEE, cost control, reliability-centred maintenance, asset condition, digitalisation, and planning & scheduling. Audits close in four to six weeks with quantified findings and a prioritised improvement roadmap. For the full methodology, visit the Assessment page.
Discuss Your Requirements
Contact us to explore scope, engagement level, and next steps.