Problem
Albany Chicago was experiencing reduced equipment availability and decreased productivity. Several processes contributing to the majority of difficulties were:
- Reactive maintenance made up the majority of maintenance activities
- Downtime hours were accumulating due to the lack of proactive and preventative efforts
- Reactive work orders dominated work order logs
- Parts availability was scarce due to inaccurate inventory reporting and forecasting data
- Lack of training was causing additional downtime hours through operator error
Solution
Advanced Technology Services (ATS) went to work to create a solution for improving Albany Chicago’s output:
- Implemented a preventive and proactive maintenance schedule for all three shifts
- Put into operation an evaluation methodology for procedure improvement
- Performed ultrasound, oil analysis, thermography and vibration monitoring predictive technologies
- Continuously updated work orders for accurate PM scheduling
- Developed an inventory system that accurately reported in-stock and out-of-stock materials
- Trained employees in Toyoda, Makino, FANUC, NTC, Visatrack – Die Cast and Clarity Net PLC and hydraulic
Bottom Line
With the help of ATS and their preventive and predictive maintenance activities, eFactory Pro™ CMMS system and continuous improvement training, the implemented programs proved successful.
- Increased proactive maintenance to 76%
- Enhanced equipment availability from 91% to 98.5% by implementing a preventative maintenance program
- Decreased reactive work orders from 82% to 24%
- Reduced downtime hours by 88%
- Increased parts availability from 13% to 80%
“The reputation that ATS has with their customers is
honesty and dedication. Even though they are ATS employees, they take pride and are committed to helping Albany Chicago reduce downtime and increase productivity.”
George Schneider, President
Albany-Chicago Company
Quarterly Average Downtime
To Quarterly Average Earned Hours