Modernizing Fleet Maintenance: The Benefits of Digital Test Suites and Training
Utility fleets across the U.S. are confronting increasing regulatory demands, rising operational costs, and the persistent challenge of training and retaining a skilled workforce. What does that mean for fleet managers? Simply put, demands for quality, compliance, efficiency and sustainability have never been greater.
That is the reality ComEd Fleet Services had in mind when they began to collaborate with Fleet Group Inc. (https://fleetgroup.com) to implement robust electronic test suites and learning programs for their fleet of over 5,000 assets. This model can offer value to other utility fleets seeking to modernize maintenance operations and ensure high performance standards.
Digital PM Inspection Forms
ComEd’s ability to maintain what has been named one of the most reliable electrical grids in the nation (see www.businesswire.com/news/home/20251110719709/en/ComEd-No.-1-in-U.S.-in-Providing-Reliable-Electric-Service-to-Customers-Benchmarking-Shows) largely depends on fast employee access to a safe, reliable and technologically sophisticated fleet of vehicles and equipment. By investing in advanced tools, technology and processes, fleets can better safeguard the workforce while reducing asset downtime.
Electronic preventive maintenance (PM) inspection forms, or digital test suites, are a cornerstone of ComEd’s collaborative efforts with Fleet Group Inc. Central to these forms are well-defined maintenance procedures that ground inspection processes in best practices. Test suites are customized for each equipment type, which has resulted in standardized, step-by-step inspection processes that bolster training consistency and streamline daily operations for technicians.
Following are some key features and benefits of the suites.
Automation and error reduction. Test suites are automatically populated with job creation data, mitigating human error in proper form selection and use. Outdated PDFs have been replaced with workflow-oriented digital forms designed to increase efficiency and ergonomic ease for inspectors. If any item fails inspection, the system is immediately prompted to generate a work request. ComEd test suites generated nearly 20,000 follow-up work requests last year.
Real-time updates. Maintenance procedures can be instantly updated to reflect evolving standards, best practices and equipment requirements, quickly providing technicians with the latest need-to-know information.
More comprehensive inspections. Digital test suites contain nearly 200 inspection points; previous forms had 120.
Integration and accessibility. ComEd digitally stores inspection records, which are instantly retrievable and follow each unit throughout its full life cycle in the fleet. This change has eliminated paper files and better streamlined audits.
Aligning e-Learning With Inspection Criteria
A standout achievement of the ComEd Fleet Services digital PM initiative has been the development and deployment of electronic learning modules that directly align with test suite inspection criteria.
The purpose of these training sessions – which include video demonstrations, knowledge checks, certification quizzes and step-by-step guidance – is to confirm that everyone from new hires to experienced technicians can adequately perform the inspections assigned to them. It is important to note here that ComEd’s e-learning system satisfies the Federal Motor Carrier Safety Administration’s inspector qualification requirements found at 49 CFR 396.19.
Additional system highlights include the following.
Standardization. E-learning modules aid in ensuring that inspection and maintenance processes and expectations are consistently adhered to across the organization.
Blended learning. Modules combine video, static images and interactive content with hands-on mentoring and practical exercises. This approach accommodates diverse learning styles so that every technician can comfortably engage with the training material.
Tracking and compliance. Integration with ComEd’s learning management system enables leadership to track fleet personnel’s completion of knowledge checks, modules and certifications.
Accessibility. E-learning content can be accessed anywhere, from any connected device, assuring that even geographically dispersed technicians can meet ComEd’s expectations. Among those expectations are compliance with relevant state and federal mandates.
Driving Operational Excellence
Electronic test suites and e-learning have helped ComEd standardize inspection and maintenance procedures, with an overarching goal of ensuring employees consistently adhere to safety protocols and legal requirements. That’s a big reason why the Fleet Services test suites must be fully completed before work orders can be closed; the rule mitigates human performance errors and drives regulatory compliance.
This approach also drives quality, allowing Fleet Services to track trends, analyze failures and continuously refine inspection criteria. Further, in transitioning to digital forms, ComEd has reduced paper consumption and minimized storage needs, an impactful improvement given the volume and frequency of maintenance reports. The utility performs over 13,000 inspections each year; environmental impacts include saving over 26,760 sheets of paper (more than three trees annually) and avoiding 0.10 metric tons of carbon dioxide.
Conclusion
With about 72 live test suites already in use, a 2025 vehicle uptime average of 98% and more e-learning modules in development, ComEd’s experience demonstrates some of the tangible benefits of digital tool use for vehicle and equipment maintenance. As your fleet plans its next phase of operational improvement, consider both options to boost technician safety, compliance, efficiency and sustainability.
About the Author: Joseph Hernandez is an accomplished fleet management professional currently employed by ComEd. He has 26 years of combined experience in mechanical, hydraulic, and electrical systems repair and maintenance, complemented by a strong background in leadership and operational oversight. Reach him at [email protected].
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ComEd’s Maintenance Modernization Journey: A 5-Point Roadmap
For utility fleet managers seeking to modernize their maintenance programs, ComEd’s experience offers this replicable five-point roadmap:
- Engage stakeholders. Collaboration among fleet, information technology, training and technical leaders is key to achieving buy-in and accuracy throughout modernization efforts.
- Digitize inspections. Replace outdated paper inspection forms with electronic test suites tailored to your fleet’s equipment and operational needs.
- Integrate training. Establish e-learning modules that mirror inspection criteria and procedures.
- Leverage data. Use digital records to analyze trends, prepare for audits and improve maintenance practices.
- Pursue sustainability. Going paperless supports climate initiatives as well as cost savings and operational flexibility.