Problem-based learning (PBL) has been used to scaffold and support student learning in many Australian medical programs, with the role of the facilitator in the process considered crucial to the overall educational experience of students. With the increasing size of student cohorts and in an environment of financial constraint, it is important to develop quality control procedures to maintain an effective and efficient PBL program and a stable tutor workforce. This paper reports on organisational practices and faculty development opportunities used to sustain facilitation quality in a large cohort PBL program. Seven strategies are proposed, built around a sound professional development program, and a suite of tactics for recruitment of, and ongoing support for, PBL tutors.