Case studies
What have we accomplished and what can you count on? Our more than 15 years of experience in maintenance speak for themselves. We are a technically minded, well-coordinated team with the ability to implement practical changes.
Digitalization of maintenance via CMMS
GOAL: End paper records, control failures and costs
ENVIRONMENT: Waste industry, 501+
STEPS:
- CMMS system selection and implementation
- Equipment structure setup, planned maintenance and failures
- Maintenance personnel training and in-service testing
- Data integration and system setup
RESULT:
- Records of all malfunctions and preventive interventions
- Reduction of parts search times and errors in records
- Clear reports on failure rates and costs
Introduction of TPM pillars, autonomous maintenance (Jishu Hozen)
GOAL: Increase equipment reliability and engage operators in preventive maintenance
ENVIRONMENT: Automotive, 1001+ (TIER 1)
STEPS:
- Baseline audit
- Proposal for change and approval by management
- Proposal for implementation of change to current status
- Training of personnel and creation of conditions for regular TPM supported by management
RESULT:
- Operator and maintenance training directly in production
- Reduction of unplanned failures by 25% within 12 months
- Improved cooperation between operators and maintenance
Establishing a new maintenance department – from scratch
GOAL: Create a fully functional internal maintenance department
ENVIRONMENT: Waste industry, Company without own maintenance – serviced externally, 501+
STEPS:
- Company without own maintenance – serviced externally
- Structure design, job descriptions and competencies
- Recruitment of key technicians
- Implementation of planned maintenance, purchase of tools and a record system
- Setting maintenance standards (5S, daily checks, reporting)
RESULT:
- Acceleration of response time to failures by 22%
- Annual savings > €65,000 on external services
- Stable team of technicians with clear responsibilities
Increase production line speed by 0.8 seconds per cycle
GOAL: Strategic elimination of weaknesses
ENVIRONMENT: Automotive, 1001+ (TIER 1)
STEPS:
- Analysis of the current state
- Measurement and statistics of all parts
- Identifying weak points and focusing on the result
- Setting the slowest parts of the device
RESULT:
- Acceleration of cycle time by 1.2 seconds
- Annual savings > €430,000 compared to baseline
- Increase in production
Increasing the speed of changing the working tool
GOAL: Reduce tool change time on an automatic welding unit by 50%
ENVIRONMENT: Automotive, 501+ (TIER 3)
STEPS:
- Analysis of the factual situation
- Implementation of corrective measures, training of personnel
- Design of a tool for optimizing the situation
- Production of the optimal tool
RESULT:
- 78% faster changeover time
- Annual savings > €12,000
- 1.9% increase in production
Reducing maintenance response time
GOAL: Reduce maintenance response time by 20%
ENVIRONMENT: Automotive, 501+ (TIER 3)
STEPS:
- Analysis of the factual situation
- Introduction of walkie-talkies and setting up communication between departments
- Optimization and training of personnel
RESULT:
- 28% faster maintenance response time
- Annual savings > €4,800
- 1.7% increase in production
Increase OEE per cycle
GOAL: Increase OEE from an average of 58% by 10%
ENVIRONMENT: Automotive, 501+ (TIER 3)
STEPS:
- Machine Analysis
- Workflow Analysis
- Analysis of other involved collaborators
- Integrate corrective actions to increase OEE
- Test actions, train workers and incorporate into standards and work procedures
RESULT:
- Increase OEE to 71%
- Cost savings, lower production costs
- Optimization of material, energy, human resource consumption.
Improving worker ergonomics
GOAL: Increase production by 10% on a selected part of the line
ENVIRONMENT: Food Industry, 101+
STEPS:
- Analysis of the facts
- Proposal of corrective measures
- Production of an optimal lifting device with a magnet at the end
- Training of personnel to work with mechanical equipment
- Creation of standards
RESULT:
- Improving ergonomics in the workplace
- Increased production by 12% in the workplace
- Optimizing the condition increased the attractiveness of the workplace
- Improving OHS
Warehouse and inventory setup
GOAL: Reduce inventory by 25%
ENVIRONMENT: Petrochemical industry, 51+, Austria
STEPS:
- Analysis of the factual situation
- Implementation of corrective measures, training of personnel
- Proposal for optimization of inventory levels
- Setting up inventory storage and FIFO standards
RESULT:
- More efficient ordering into stock
- Annual savings > €28,000
- Warehouse space savings of > 300m¨¨˘˘˘^2
Increasing cooling efficiency
GOAL: Increase the efficiency of chillers by 3°C
ENVIRONMENT: Petrochemical industry, 51+, Austria
STEPS:
- Analysis of the factual situation
- Setting the angle of inclination of the blades of industrial fans
- Setting up predictive maintenance on the device by measuring vibration and flow
- Training of personnel
RESULT:
- More efficient cooling by 5°C at 20°C and the conditions in question
- Annual savings > €7,000
- Increase production to values from 10 years ago
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