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Boosting Equipment Uptime in component Production

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OY Consulting Services

Case Study

Boosting Equipment Uptime in component Production

The client was experiencing frequent equipment breakdowns and low uptime—averaging below 80%—across critical ammunition production lines. A reactive maintenance culture, limited visibility into MTTR/MTBF metrics, and high spare part costs were negatively impacting throughput, product quality, and export commitments.

Achieved a significant increase in equipment availability—from 78% to 92%—through structured TPM and preventive maintenance implementation.
Lowered equipment breakdowns by 40%, driven by root cause analysis training, standardized failure reporting, and technician-led improvements.
Saved USD 100,000 annually by localizing critical spare parts sourcing and improving maintenance planning, while also achieving 95% PM compliance.
Project Info
Confidential
Maintenance & Reliability Consultant
Equipment Reliability & Uptime Optimization
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Approach & Execution

Phase 1: Baseline Assessment

Conducted OEE benchmarking and tracked MTTR/MTBF across key assets.
Performed Pareto analysis to identify high-impact failure modes

Phase 2: TPM Strategy Deployment

Introduced structured preventive maintenance (PM) routines (daily/weekly/monthly)
Implemented visual management boards and operator-assigned maintenance tasks
Established a localized inventory system for critical spare parts

Phase 3: RCA Culture & Capability Building

Trained technicians in 5 Whys, Fishbone Diagrams, and Fault Tree Analysis
Defined maintenance KPIs and standardized failure reporting protocols
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Tools & Frameworks

  • Lean Tools: TPM, 5S, Kanban
  • Analytics & Tracking: MTTR/MTBF dashboards, CMMS logs
  • Problem Solving: Pareto Analysis, RCA Tools
  • Planning: Maintenance Planning Matrix

Workforce Engagement

Conducted daily standups and used line-level visual boards for transparency
Empowered technicians to redesign PM checklists based on real-world insights
Launched a recognition program for zero-downtime shifts to boost morale

Results

Increased equipment availability from 78% to 92%
Reduced breakdown frequency by 40%
Saved USD 100,000 annually through local sourcing of critical spares
Achieved 95% PM compliance rate
Improved technician morale and retention through engagement and recognition
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