Maintenance Strategy Optimization for a Polymer Currency Printing Company

When a leading polymer currency printing company began experiencing significant downtime on a mission-critical asset, they turned to Nexus Global for expert support. The challenge was not just about restoring uptime but about building a sustainable asset management strategy 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.

To achieve these goals, Nexus Global developed a tailored program using Consequence Driven Maintenance (CDM) combined with PM Optimization (PMO). 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 to discover how Nexus Global designed and implemented a customized maintenance strategy that delivered measurable improvements and set the stage for future reliability gains.