In the heartland of America, a well-known beef processing plant embarked on a journey toward operational excellence. Founded in the mid-'90s, this company had quietly grown, acquiring a substantial processing plant in the early 2000s. However, beneath the surface lay maintenance savings challenges that threatened to hinder its progress.
Maintenance operations were a reactionary maze, lacking a systematic approach, vital tools, and a culture of accountability. Engaging POWERS for a transformative intervention, they sought to chart a new course and achieve significant maintenance savings.
The story of this transformation serves as a testament to the power of strategic intervention and the boundless potential within every organization for growth and excellence.
Due to the absence of daily metric tracking, this processing giant operated reactively. Supervisors spent a significant amount of time on mechanical work due to a lack of trained mechanics, leaving inadequate supervision of the crews. Work assignments were inconsistent, and crews were on standby for crisis work after completing startup checklists.
Before engaging POWERS, this beef processing plant faced several maintenance performance issues:
- Existing Preventive Maintenance (PM) procedures were rudimentary, resembling startup and shutdown checklists.
- The maintenance environment operated in a reactive “run to fail” mode with no root cause analysis after equipment failures.