Background

A mid-sized food manufacturing company struggled with frequent equipment breakdowns, leading to significant production losses and spoilage. Their maintenance approach was entirely reactive: they operated under a “run-to-failure” model, addressing issues only when equipment failed. This approach resulted in unplanned downtime, inefficient resource allocation, and escalating costs. Additionally, there was no criticality assessment to prioritize key assets, and spare parts management was chaotic, often leading to delays in repairs due to unavailable components.

The Challenge

The lack of a preventative maintenance strategy caused:

• Frequent breakdowns and extended downtime.
• Production rate losses and product spoilage.
• Increased maintenance costs due to emergency repairs and expedited parts delivery.
• Frustration among the workforce, who were constantly “firefighting” problems rather than performing structured maintenance.

The company needed a structured asset management strategy that aligned with their limited workforce and budget, ensuring reliability and efficiency.

The Solution

The company engaged IDS to overhaul their maintenance strategy. IDS conducted a comprehensive review of their operations and identified several critical gaps:

1. Lack of Preventative Maintenance: No measures were in place to prevent failures before they occurred.
2. No Asset Criticality Assessment: All equipment was treated equally, leading to inefficiencies in resource allocation.
3. Poor Spare Parts Management: Unorganized inventory management delayed repairs.

IDS proposed a tailored solution:

• Asset Criticality Assessment: Key assets were identified and prioritized based on their impact on production and likelihood of failure.
• Remote Maintenance Planning Program: IDS implemented a program that provided detailed maintenance schedules remotely, reducing the burden on the in-house workforce.
• Spare Parts Inventory System: A streamlined spare parts management system was introduced, ensuring critical components were always available.
• Training and Support: The workforce received training on the new systems, ensuring smooth implementation and long-term sustainability.

Results

Within two years of implementing the new maintenance strategy, the food manufacturer achieved remarkable improvements:

• 15% Reduction in Unplanned Downtime: Preventative maintenance schedules significantly decreased equipment failures.
• Improved Production Efficiency: With fewer breakdowns, the company experienced fewer rate losses and reduced spoilage.
• Cost Savings: Predictable maintenance schedules and efficient spare parts management lowered emergency repair costs.
• Workforce Productivity: Employees transitioned from reactive repairs to planned maintenance, enhancing morale and effectiveness.

Conclusion

This case highlights the transformative impact of a structured asset strategy tailored to a company’s unique needs. By partnering with IDS, the food manufacturer shifted from a reactive to a proactive approach, improving operational reliability and achieving measurable success. This demonstrates that even with workforce and budget constraints, a strategic approach to maintenance can drive significant operational and financial benefits.