Case Study: Achieving a 22.6% Reduction in Annual Maintenance Costs for a Sheet Metal Company

Introduction:

In the realm of sheet metal production, the reliance on heavy equipment operating at extreme temperatures underscores the critical importance of equipment reliability and maintenance. Failures can lead to production line stoppages, requiring cooling before maintenance interventions can occur. Recognizing these challenges, our sheet metal company sought to enhance equipment reliability and reduce maintenance costs through strategic optimization.

Optimization Steps:

Collaborating with BQR consulting and leveraging the advanced capabilities of apmOptimizerTM software, our team embarked on a comprehensive optimization process. The key steps included:

1. Analysis of Production Lines and Model Development: Engaged in collaborative efforts with on-site staff, we meticulously analyzed production lines and developed a robust reliability and logistics model. This step was crucial in understanding the intricacies of the equipment and its impact on production.

2. Life Cycle Cost (LCC) Calculation and Identification of Key Drivers: Employing sophisticated methodologies, we calculated the Life Cycle Cost (LCC) and identified pivotal factors contributing to downtime and overall cost implications. This step provided a comprehensive overview of the economic landscape associated with the equipment's life cycle.

3. Optimization of Inspections and Spare Parts Provisioning: With a granular understanding of cost drivers, our team strategically optimized inspections and spare parts provisioning. This involved streamlining the maintenance process to minimize LCC, ensuring a proactive and cost-effective approach to equipment upkeep.

Results:

The meticulous implementation of optimization strategies yielded significant results, with the sheet metal company realizing a remarkable 22.6% reduction in annual maintenance costs. This achievement stands as a testament to the effectiveness of the collaborative efforts, advanced modeling, and strategic decision-making facilitated by BQR consulting and apmOptimizerTM software. The company now enjoys improved equipment reliability, minimized downtime, and enhanced cost-effectiveness in its maintenance practices.