Challenge: In a challenged economy, a maintenance organization was tasked to take their reliability and budget performance to a higher level, as the historical trends were leading to the lowest cost performance in their history.
Solution: The team was empowered to identify gaps in each of their departments and as a result, they charted action plans to remove the waste that existed amongst their work process. The team’s charted activities were managed by a 6 Sigma methodology in where leading and lagging key performance indicators were established to monitor progress. They focused on schedule delays, work order backlog, PPM optimization and reliability top opportunities/repetitive maintenance.
Results: Within a three year period, the team was able to optimize the use of maintenance resources, drive innovation and technology growth and improve upon their reliability strategies, which resulted in 42% reduction in maintenance cost (labor, materials and rentals) while also safely (Zero OSHA Injuries) achieving a 1.85% increase in mechanical reliability performance.
Impact: $9 million
mAINTENANCE PRODUCTIVITY CASE STUDIES
This section of case studies feature improvements that align to increasing maintenance productivity.