ATS Skilled Technicians Drive Production Success

Navigating market fluctuations and staffing challenges

In 2024, a leading agricultural heavy equipment manufacturer encountered significant challenges due to fluctuations in market demand. These fluctuations complicated product forecasting and made staffing adjustments difficult. The surge in demand led to a substantial backlog of tractors requiring rework, with each tractor already purchased by end-customers. After production units rolled off the assembly line, the manufacturer’s quality team would find numerous issues during their inspection, including:

  • Paint defects
  • Decal errors
  • Hydraulic leaks
  • Electrical malfunctions
  • Missing parts
  • Engine or transmission problems

Addressing this diverse range of rework required technicians to have a broad set of technical skills. The manufacturer faced challenges in hiring qualified personnel to manage and overcome the backlog. Additionally, the need for flexibility in adjusting team sizes based on fluctuating demand further complicated the situation. To address these pressing issues, the manufacturer partnered with ATS to provide a reliable and skilled workforce.

Initial challenges

Tractors in backlog

A surge in demand resulted in a backlog of 800 tractors awaiting rework due to numerous quality issues.

The increased demand created a need to find additional personnel to support rework on the production line.

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Overcoming production hurdles

Due to a shortage of skilled operators, the manufacturer faced a significant backlog, jeopardizing production goals. The ATS team successfully transformed the manufacturer’s maintenance approach from reactive to proactive by addressing challenges through a comprehensive assessment and implementing several key initiatives:

  • Deploy production operators to prevent and alleviate production backlog.
  • Collaborate with customer’s management team to determine necessary shift support.
  • Consistently assess new processes for continuous improvement opportunities.

Strategic shifts drive long-term success

ATS was seamlessly integrated into the manufacturer’s production teams, working closely with management to address production challenges and ensure support for both first and second shifts. This partnership enabled the manufacturer to adapt to market fluctuations and customer demands, reducing their backlog.

  • Overcome Data and Team Silos
    Team expansion

    Production operator team was expanded, growing from 15 to 172 members.

  • Human Resource Constraints
    Backlog reduction

    Tractor backlog reduced from 800 to 50.

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