Challenge: A maintenance service group within a manufacturing plant had an excessive "Cost -to-Serve" model that was putting the department in an noncompetitive position. There was no idea on how they could improve on their performance and also deliver a service that was lower than competing contract companies.
Solution: Following a process improvement methodology such as "Six Sigma" can help in reducing your Cost-to-Serve. Defining the defect, measuring/observing the process, analyzing the data, improving on the opportunities and controlling the changes is the process that the team used to make a positive impact on the bottom-line.
Results: The project yielded a 62% reduction in waste and $105,000 in annual savings. The team updated the Operating Discipline and developed a Control Plan with Standard Work Instructions on how to perform the testing service. They also introduced a new service database and updated engineering drawings so that the administrative workload could decrease.
mAINTENANCE PRODUCTIVITY CASE STUDIES
This section of case studies feature improvements that align to increasing maintenance productivity.