Case Study

• Reactive approach—Equipment was often run to failure, causing expensive downtime during critical periods.
• Lack of data tracking—No system in place for equipment downtime, repeat failures, or technician efficiency.
• High costs & waste—Spare parts were misplaced, inventory was inaccurate, and repairs were unplanned.
• Low credibility—Operations and leadership viewed maintenance as unreliable and ineffective.

Solution: Building a Predictive, Data-Driven Maintenance System

Using the A.E.I. Success Framework, the transformation began by focusing on:

1️⃣ Alignment – Establishing the Vision & Goals

✔ Identified key recurring equipment failures (“bad actors”) and root causes.
✔ Defined clear goals: track failures, analyze trends, and implement permanent solutions.
✔ Secured buy-in from leadership and operations by proving the value of a proactive approach.

2️⃣ Execution – Implementing Technology & Processes

✔ Installed a PLC data historian to capture real-time equipment data.
✔ Built out network, Wi-Fi, Bluetooth, and IoT monitoring for remote diagnostics.
✔ Created a real-time maintenance dashboard to track uptime % and failure patterns.
✔ Deployed a new CMMS (Computerized Maintenance Management System) to log and analyze failures.
✔ Standardized repair processes and increased personnel training on predictive maintenance.

3️⃣ Improvements – Driving Continuous Optimization

✔ Monthly tracking of actual maintenance costs vs. projections to measure ROI.
✔ Enhanced spare parts inventory management, reducing waste and loss.
✔ Increased scheduled maintenance from 5% to over 30%, preventing failures before they occurred.
✔ Continuously refined the “bad actor” tracking system, ensuring repeat issues were eliminated.

Results: A Best-in-Class Maintenance Function

✅ 80%+ reduction in annual maintenance costs—lower expenses through smarter planning.
✅ First-ever accurate spare parts inventory—eliminating waste and confusion.
✅ 30%+ of maintenance work now scheduled in advance—a 6x improvement in proactive maintenance.
✅ Earned credibility & respect from operations and leadership—maintenance became a strategic partner.

Key Takeaways & Lessons Learned
• Small, incremental improvements lead to transformational results.
• Goal-setting and execution drive compounding success.
• Technology + Process + Training = Sustainable Operational Excellence.
• The A.E.I. Success Framework is a repeatable formula for operational improvement.

How This Applies to Your Business

If your company is struggling with high costs, reactive maintenance, or unreliable processes, applying this structured Alignment → Execution → Improvements methodology can drive similar results.