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Restoring operational stability through proactive maintenance
A large manufacturing plant in the eastern United States faced frequent HVAC breakdowns that disrupted production and drove up maintenance costs. By implementing an Asset Lifecycle Management Program, the plant achieved consistent uptime, reduced repair expenses, and improved overall operational efficiency, creating measurable economic value and production reliability.
Impact Highlights
100% on-time preventative maintenance
$773,280 annual maintenance and repair cost reduction
Estimated $40M improvement in production output
Maintaining uptime in a facility with aging HVAC assets
Built in the early 1900s, the manufacturing plant spans hundreds of acres and operates more than 450 HVAC assets, including chillers, boilers, rooftop units, and cooling towers. Frequent equipment failures caused production downtime and nearly 13,000 hours of annual maintenance and repairs. The incumbent service provider lacked the expertise and responsiveness needed to ensure reliability, leaving the plant vulnerable to costly emergency repairs and lost manufacturing output.
Implementing an asset lifecycle management program for long-term reliability
The manufacturing plant introduced an Asset Lifecycle Management Program designed to restore operational stability and reduce total cost of ownership. The approach combined people, processes, and technology to deliver measurable results:
- Technicians supported by a local account manager and site manager ensured clear communication and accountability.
- Quarterly business reviews tracked performance against KPIs and aligned stakeholders on goals.
- Scheduled service and rapid response protocols minimized downtime and extended asset life.
- A Computerized Maintenance Management System (CMMS) automated documentation, tracked costs, and informed capital planning.
Driving measurable savings and production reliability
Within the first year, the Asset Lifecycle Management Program delivered significant improvements to the manufacturing plant, ensuring that the plant could maintain consistent operations while controlling costs:
- $773,280 annual maintenance and repair cost reduction compared to the previous provider
- 50% fewer maintenance and repair hours · $200,000 annual chiller rental cost avoidance
- Estimated $40M improvement in production output due to increased equipment uptime
- 100% completion of scheduled service extended asset life
- Two consecutive quarters without after-hours requests.
- Targeted repairs avoided $300,000 in asset replacement costs.
About the large manufacturing plant
A major U.S. manufacturing company committed to improving operational reliability and reducing total cost of ownership through proactive maintenance and technology-driven asset management.
About the facility
- Large manufacturing plant in the eastern United States
- Built in the early 1900s, spanning hundreds of acres
- Operates more than 450 HVAC assets, including chillers, boilers, and cooling towers
