Evaluating NAVFAC'S Preventive Maintenance Strategy: Cost Effectiveness and Life Cycle Impacts on Equipment Longevity

Abstract

This thesis examines the cost-effectiveness and life cycle outcomes of the Naval Facilities Engineering Systems Command’s (NAVFAC) standardized preventive maintenance (PM) plans compared to Original Equipment Manufacturer (OEM)-guided PM plans. Using a statistical analytical approach that incorporates Robert Snow Means costing, Consumer Price Index adjustments, and Uniform Classification of Construction Systems and Assemblies (UNIFORMAT) coded MAXIMO asset records, the study analyzes over $1.2 million in material and labor costs across more than 7,152 PMs, 5,725 emergency, urgent, and routine work orders (EUR WOs), and 3,659 assets from fiscal year 2020 to fiscal year 2024. Only 2.29% EUR WOs were traceable to specific assets, highlighting data limitations. HVAC systems (D30) represented 93.7% of all PMs and 63.9% of PMs with cost data. On average, NAVFAC-standard PMs cost $173.82 per task, while OEM-guided PMs were modeled at $439.01—2.5 times higher. NAVFAC PMs, though more affordable, underperformed in extending asset longevity for complex subsystems. Findings support a hybrid strategy, applying OEM frequencies to high-value or aging systems and NAVFAC standard PMs to low-risk assets. Recommendations include refining PM tracking procedures, prioritizing critical assets using asset age and design life, and piloting dynamic PM plans to improve life cycle cost control and operational readiness.