Manufactoring
Strategic Maintenance and Inventory Management for Sustainable Results
Building A Foundation of Operational Excellence
How Streamlined Asset Management and Inventory Control Delivered Consistent, Measurable Gains
- Cut packaging operating costs by $1M/year.
- Achieved >95% service levels in spare parts inventory management.
- Revamped asset care program to align with demand (PM, autonomous maintenance, condition monitoring, parts swaps).
- Established and implemented control metrics across 50 plants.
At a major manufacturing operation, a strategic transformation in asset management delivered striking results. Focusing first on their packaging line, the team drove down annual operating costs by $1 million. Rather than relying solely on cuts, they built a proactive maintenance culture supported by preventive maintenance routines, autonomous maintenance practices, and timely parts swaps, ensuring the line could consistently meet growing demand.
We saved $1M annually and exceeded 95% spare parts service levels—without compromising quality.
Beyond this production line, the company reevaluated spare parts inventory management. By refining processes and setting clear priorities, they increased service levels above 95%, guaranteeing critical components were available without bloated inventories. The impact was felt company-wide as the team introduced key performance metrics across 50 plants, establishing clear standards for efficiency and quality.
Together, these measures formed a robust foundation for operational excellence. They not only curbed costs but also extended reliability and performance far into the future. This holistic, data-driven approach positioned the manufacturing operation to adapt swiftly, maintain high-quality outputs, and evolve as market conditions changed.
