Cutting unplanned downtime by 31% on a continuous-process line.
Continuous-process plant had 4.2% unplanned downtime against 1.8% peer benchmark. TPM rebuild + maintenance reorganization in 8 months.
31%
Unplanned downtime reduction
+12pts
Asset utilization lift
$19M
Annualized savings
0
Lost-time injuries
The starting condition.
Continuous-process building materials plant had 4.2% unplanned downtime — peer benchmark was 1.8%. Each downtime hour cost $42K in lost throughput and overtime recovery cost.
What we did,
in order.
- 01
Maintenance organization redesign: separation of routine, planned, and breakdown work.
- 02
Reliability-centered maintenance (RCM) deployed on top 14 critical assets.
- 03
Operator-driven autonomous maintenance program for 38 routine PMs.
- 04
Maintenance planning function built — previously did not exist.
- 05
Spare parts strategy redesigned with criticality-based stocking levels.
What was sustained,
at month twelve.
- 31% reduction in unplanned downtime, sustained at month 12
- +12 percentage points asset utilization lift
- $19M annualized savings from recovered throughput and reduced overtime
- Zero lost-time injuries during engagement
- Maintenance function reorganized with internal planner role permanently added
Your operation,
your case study.
Engagements like this one start with a 45-minute conversation and a written brief — before either of us commits to anything.
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