Shortening Downtime by 14.3% for a Parts Manufacturer
We implemented a preventive maintenance system and trained 28 operators. The number of sudden failures dropped nearly to zero.
We changed the way work is done at the Mech-Art hall in Krakow. Instead of waiting for a failure, we started preventing it because we count every penny for our client. The result is a fact: machines work 14.3% longer every working month.
The challenge
The plant had a serious problem with two large CNC milling machines that were the heart of production. They broke down an average of 4 times a month, which paralyzed the rest of the processes. Every hour of downtime meant 840 PLN in pure loss for the owner, not counting penalties for delivery delays.
In July 2024, machines were down for a total of 51 hours. The staff had no clear procedures and didn't know how to react to early signs of part wear. External service arrived at the earliest two days after notification, which was unacceptable given current contracts.
Our approach
Marek Jaworski personally checked service logs and repair expenses from the last 7 months. We assigned two of our industrial process specialists to the project. We conducted a hard technical audit of the milling machines and found the cause – the lubrication system was failing due to operation errors.
We organized workshops directly at the machines for 28 operators. We showed them 5 critical points they must check within 4 minutes before the start of the shift. We check facts, not promises, so every employee had to perform an inspection independently under our watch.
The solution
We introduced a quick response system based on simple checklists. If an operator sees a concerning leak, the machine goes for a 15-minute technical inspection instead of working until it completely seizes.
We also set up a stock of the most needed spare parts directly on the floor. We invested 12,380 PLN from the renovation budget, which allowed shortening the repair time for minor faults from 48 hours to just 47 minutes. Zero fluff – we simply gave people the tools they needed.
Results
After three months of work, the plant's efficiency noticeably jumped. The plant earns more because the machines simply do their job without unexpected breaks. Facts on the table: operators stopped fearing that production would stop in the middle of an important night order.
Timeline
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August 12, 2024Analysis of downtime costs and service logs from the entire half-year.
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September 2, 2024Technical audit of milling machines and job training for 28 operators.
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October 15, 2024Launch of a handy spare parts warehouse on the floor.
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November 28, 2024Completion of measurements and delivery of savings report.
"Previously, machines lived their own lives and broke at the worst moments. Now we know what to do before something snaps. This is real money that stays in the company."