Top 7 Signs a Fleet Needs a Better PM Program (Before It Costs You Thousands)

Seven warning signs your fleet PM program is failing and how to fix it before breakdowns get expensive.

Warning sign #1: You only touch trucks when they break

If most of your maintenance happens after a driver reports a problem, your PM program is already behind.

Warning sign #2: No single list of units and PM due dates

If you have to dig through invoices or notes to know when a unit is due, PM can easily slip.

Warning sign #3: Techs are spending more time on breakdowns than PM

When most of your shop or mobile hours are going to road calls and emergency repairs, that’s a red flag. A healthy PM program keeps your team focused on planned maintenance in the yard, not chasing the same failures over and over again on the side of the road.

Warning sign #4: Drivers have their own “unofficial” maintenance process

If drivers are deciding when to report issues, choosing which units to run, or skipping DVIRs because “it always has that noise,” your PM program isn’t in control. A clear, simple process for reporting defects and pulling units out of service keeps small problems from turning into on-road events.

Warning sign #5: You can’t quickly see cost per mile by unit

When repair spend is just one big number, problem trucks hide in the average. If you can’t pull cost-per-mile or repair spend per unit, it’s almost impossible to see which trucks are draining profit or need to be retired or repurposed.

Warning sign #6: PM intervals are the same for every unit

Different routes, loads, and duty cycles beat trucks up in different ways. If every unit is on the same interval regardless of how it’s used, some trucks will be over-serviced and others under-protected. A better PM program adjusts intervals based on how the truck actually works.

Warning sign #7: You only talk about PM when something has gone wrong

When PM only comes up after a roadside breakdown, failed DOT inspection, or angry customer call, it’s a sign maintenance is stuck in reactive mode. Strong fleets review PM completion, repeat defects, and inspection findings regularly so problems get fixed in the yard—not on the shoulder.