PROBLEM:
A leading industrial component manufacturer was experiencing high cost and lost productivity due to inefficiencies in maintenance and machine repair procedures. The absence of spare parts, documentation scattered throughout the plant and no CMMS tracking system took its toll resulting in high equipment downtime. Disorganized parts cribs created long repair times. And the reactive maintenance program resulted in lost productivity and higher costs.

THE ATS SOLUTION:
ATS went to work installing a CMMS system to address and monitor the machine productivity, spare parts and preventive maintenance processes issues listed above. Along with "best practices" including cleaner, well-organized part cribs, there was an immediate reduction in time searching for parts to repair equipment. Centralizing documentation decreased time searching for manuals and increased technician wrench time. ATS increased predictive maintenance using thermography, ultra-sound and oil analysis--this in addition to establishing a preventive maintenance program.

THE BOTTOM LINE:
The manufacturer saw an increase of preventive maintenance from 25% to 50%, which resulted in a productivity increase of 36% in one year. The plant dropped from 55 hours of downtime per day to 35 hours, a 36% reduction. This reduction in downtime resulted in $750,000 additional product revenue on an annualized basis. A quality improvement was implemented and scrap was reduced, eliminating costs by $1000 per day, $250,000 per year. This manufacturer saw a net benefit of $1,000,000 in the course of one year, nearly 2% of their $50 million annual output.