--- title: Maintenance Strategy Optimization for a Polymer Currency Printing Company description: "Case Study: How an improved PM Optimization (PMO) Strategy on a critical asset increased efficiency, cut costs, and reduced downtime by 40% in 90 days." image: https://blog.nexusglobal.com/hubfs/Case%20Study%20CTAs/CCL%20Image%201408x833.png --- [Skip to the main content.](https://blog.nexusglobal.com/reduced-downtime-by-40-with-cdm/pmo-strategy-reboot#main-content) [![Nexus Logo PNG White](https://blog.nexusglobal.com/hs-fs/hubfs/Nexus%20Logo%20PNG%20White.png?width=1600&height=645&name=Nexus%20Logo%20PNG%20White.png "Nexus Logo PNG White")](https://www.nexusglobal.com) [![Nexus Logo PNG Black](https://blog.nexusglobal.com/hs-fs/hubfs/Nexus%20Logo%20PNG%20Black.png?width=1600&height=645&name=Nexus%20Logo%20PNG%20Black.png "Nexus Logo PNG Black")](https://www.nexusglobal.com) - [Software](https://www.nexusglobal.com/software) - Business Optimizer - Data Optimizer - Strategy Optimizer - Planning Optimizer - 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The challenge was not just about restoring uptime but about building a sustainable [asset management strategy](https://www.nexusglobal.com/apmsolutions/strategy-management) that addressed the bigger picture. The client needed a cost-effective preventive maintenance (PM) program that considered known failure modes, potential consequences, and the likelihood of each failure occurring. Beyond the equipment itself, the strategy also had to account for people, processes, leadership alignment, and a framework for [continuous improvement.](https://blog.nexusglobal.com/continuous-improvement) To achieve these goals, Nexus Global developed a tailored program using **Consequence Driven Maintenance (CDM)** combined with [PM Optimization (PMO)](https://blog.nexusglobal.com/pm-optimization-6x-faster-than-rcm). This methodology identifies both expected and unacceptable failures while revealing opportunities to improve performance and reduce inefficiencies. The new strategy balanced cost, risk, equipment availability, and operational performance—helping the client achieve greater reliability across their critical assets. This case study highlights how a structured and data-driven approach can transform maintenance programs, even in highly specialized industries like currency printing. By aligning maintenance with organizational goals, Nexus Global helped the client not only reduce downtime but also create a foundation for long-term success. [**Download the full case study**](https://blog.nexusglobal.com/hubfs/Case%20Studies%20and%20Whitepapers/SM%20Case%20Study%20-%20Major%20Note%20Printing%20Company.pdf) to discover how Nexus Global designed and implemented a customized maintenance strategy that delivered measurable improvements and set the stage for future reliability gains. ### What is maintenance strategy optimization? Maintenance strategy optimization is the process of evaluating and improving maintenance activities to ensure they address relevant failure modes, risks, and operational requirements. The goal is to create a maintenance program that balances reliability, asset availability, cost, and risk while eliminating unnecessary or ineffective work.  ### What is Consequence Driven Maintenance (CDM)? Consequence Driven Maintenance (CDM) is a structured approach that considers potential equipment failures and the consequences associated with those failures. It helps organizations focus maintenance resources on the failure modes that present the greatest operational or business impact while developing appropriate strategies for managing risk.  ### How does PM Optimization improve preventive maintenance? PM Optimization (PMO) evaluates existing preventive maintenance activities to determine whether they effectively address known failure modes at the appropriate frequency. It can identify unnecessary tasks, ineffective activities, maintenance gaps, and opportunities to improve task intervals, helping organizations create a more efficient and effective PM program.  ### How can maintenance strategy optimization reduce equipment downtime? An optimized maintenance strategy helps teams identify critical failure modes and establish appropriate preventive, predictive, or other maintenance activities before failures disrupt operations. By focusing maintenance resources on the right work, organizations can improve equipment availability while reducing unnecessary downtime and maintenance effort.  ### Why should maintenance strategies consider failure consequences and likelihood? Not every equipment failure carries the same level of risk. Evaluating both the likelihood of a failure and its potential consequences helps organizations determine where maintenance resources provide the greatest value. The approach used in this engagement considered known failure modes, potential consequences, and the likelihood of those failures occurring  ### How does continuous improvement support a maintenance strategy? Maintenance strategies should evolve as equipment performance, failure history, operating conditions, and organizational priorities change. Capturing performance data and lessons learned allows teams to continuously refine maintenance activities and ensure the strategy remains aligned with reliability and business objectives. Continuous improvement was specifically incorporated into the framework developed for this project.  - [Tweet](https://twitter.com/share) [![How a Brewery Improved Maintenance Strategy on Its Bottling Line](https://blog.nexusglobal.com/hubfs/Case%20Study%20CTAs/Case%20Study%20CTAs5.jpg)](https://blog.nexusglobal.com/how-a-major-brewery-and-bottling-company-reduced-annual-maintenance-labor-by-650-hours) #### [How a Brewery Improved Maintenance Strategy on Its Bottling Line](https://blog.nexusglobal.com/how-a-major-brewery-and-bottling-company-reduced-annual-maintenance-labor-by-650-hours) [![Picture of Doug Robey | CMRP, CRL](https://app.hubspot.com/settings/avatar/956dd448a701e49e9f8bd4c5381c0b29) Doug Robey | CMRP, CRL](https://blog.nexusglobal.com/author/doug-robey-cmrp-crl) Discover how a brewery reduced annual maintenance labor by 650 hours through optimized strategies and improved plant throughput. [STRATEGY MANAGEMENT](https://blog.nexusglobal.com/tag/strategy-management) [CASE STUDY](https://blog.nexusglobal.com/tag/case-study) [MANUFACTURING](https://blog.nexusglobal.com/tag/manufacturing) [ASSET PERFORMANCE MANAGEMENT (APM)](https://blog.nexusglobal.com/tag/asset-performance-management-apm) [PMO](https://blog.nexusglobal.com/tag/pmo) [STRATEGY OPTIMIZER](https://blog.nexusglobal.com/tag/strategy-optimizer) [RELIABILITY](https://blog.nexusglobal.com/tag/reliability) [MAINTENANCE STRATEGY](https://blog.nexusglobal.com/tag/maintenance-strategy) [Read More](https://blog.nexusglobal.com/how-a-major-brewery-and-bottling-company-reduced-annual-maintenance-labor-by-650-hours) [![PM Route Program Delivered in Expedited Time at Major Paper Mill](https://blog.nexusglobal.com/hubfs/Featured%20Images/Created-Effiencient-PM-Routes-in-Expedited-Time.jpg)](https://blog.nexusglobal.com/created-efficient-pm-routes-in-expedited-time) #### [PM Route Program Delivered in Expedited Time at Major Paper Mill](https://blog.nexusglobal.com/created-efficient-pm-routes-in-expedited-time) [![Picture of Doug Robey | CMRP, CRL](https://app.hubspot.com/settings/avatar/956dd448a701e49e9f8bd4c5381c0b29) Doug Robey | CMRP, CRL](https://blog.nexusglobal.com/author/doug-robey-cmrp-crl) Nexus Global delivered a PM Route Program to a major pulp & paper manufacturer using a robust and cost effective method for PM Optimization (PMO). [STRATEGY MANAGEMENT](https://blog.nexusglobal.com/tag/strategy-management) [CASE STUDY](https://blog.nexusglobal.com/tag/case-study) [MANUFACTURING](https://blog.nexusglobal.com/tag/manufacturing) [ASSET PERFORMANCE MANAGEMENT (APM)](https://blog.nexusglobal.com/tag/asset-performance-management-apm) [PMO](https://blog.nexusglobal.com/tag/pmo) [STRATEGY OPTIMIZER](https://blog.nexusglobal.com/tag/strategy-optimizer) [RELIABILITY](https://blog.nexusglobal.com/tag/reliability) [MAINTENANCE STRATEGY](https://blog.nexusglobal.com/tag/maintenance-strategy) [Read More](https://blog.nexusglobal.com/created-efficient-pm-routes-in-expedited-time) [![Oil & Gas Company Improves Maintenance Strategy for Mainline Units](https://blog.nexusglobal.com/hubfs/Case%20Study%20CTAs/Case%20Study%20CTAs.jpg)](https://blog.nexusglobal.com/how-a-major-oil-gas-company-reduced-maintenance-annual-labor-costs-on-mainline-units-228k) #### [Oil & Gas Company Improves Maintenance Strategy for Mainline Units](https://blog.nexusglobal.com/how-a-major-oil-gas-company-reduced-maintenance-annual-labor-costs-on-mainline-units-228k) [![Picture of Doug Robey | CMRP, CRL](https://app.hubspot.com/settings/avatar/956dd448a701e49e9f8bd4c5381c0b29) Doug Robey | CMRP, CRL](https://blog.nexusglobal.com/author/doug-robey-cmrp-crl) Oil & Gas company reduces maintenance labor costs and improves uptime with Nexus Global's Strategy Management review of Planned Maintenance. [STRATEGY MANAGEMENT](https://blog.nexusglobal.com/tag/strategy-management) [CASE STUDY](https://blog.nexusglobal.com/tag/case-study) [ENERGY & UTILITIES](https://blog.nexusglobal.com/tag/energy-utilities) [ASSET PERFORMANCE MANAGEMENT (APM)](https://blog.nexusglobal.com/tag/asset-performance-management-apm) [PMO](https://blog.nexusglobal.com/tag/pmo) [RELIABILITY](https://blog.nexusglobal.com/tag/reliability) [MAINTENANCE STRATEGY](https://blog.nexusglobal.com/tag/maintenance-strategy) [OIL & GAS](https://blog.nexusglobal.com/tag/oil-gas) [Read More](https://blog.nexusglobal.com/how-a-major-oil-gas-company-reduced-maintenance-annual-labor-costs-on-mainline-units-228k) Nexus Global Business Solutions, Inc. Nexus Global Business Solutions, Inc. 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