Automotive manufacturing plant streamlines facility operations and maintenance

The automotive manufacturing plant needed to maintain high production standards while managing a complex facility with thousands of HVAC assets. Leadership wanted to outsource facility operations and maintenance, as well as environmental code compliance, to an expert team that could provide flexibility in both cost and manpower. This would enable plant personnel to focus on production equipment and manufacturing activities.

Building on a relationship spanning more than 20 years, Johnson Controls expanded its support through a $1 million annual O&M contract signed in 2020. The agreement combined facility operations and maintenance, environmental compliance support, building automation, predictive maintenance and monitoring, refrigerant tracking, and YORK® HVAC equipment installation and equipment upgrades.

Johnson Controls maintains an on-site presence with up to 10 embedded staff members and additional local resources available as needed. The team supports facility performance through building automation, connected equipment, environmental process documentation, refrigerant tracking, compliance reporting, and regular performanc reviews with plant leadership.

By integrating the facility's Metasys system with sensors installed on critical equipment, the plant reduced scrap rates for temperature-critical processes and gained real-time monitoring capabilities without the need for daily visual inspections. Predictive maintenance helps identify and address potential equipment issues before they lead to costly repairs or production disruptions.

Integrated HVAC asset data helps plant managers make informed decisions and prioritize projects that support business outcomes. Johnson Controls also supports capital planning and project management processes through recommendations to the leadership team.

When the facility needed to minimize costs to align with demand, technology implementation, automation and staffing adjustments resulted in a guaranteed 10% yearover-year reduction in costs while increasing energy savings by up to 50%. The program also helps extend HVAC asset life, improve compliance, and support a safe manufacturing environment.