The Challenge
A 40-unit mixed fleet operating on reactive maintenance was experiencing 3–5 unplanned equipment failures per month, each averaging $85,000 in lost production and emergency repair costs. The operation had no structured service program and was relying entirely on operator-reported issues.
Our Approach
We conducted a full fleet audit using OEM service data and telematics history, identified the 12 highest-risk units, and built a tiered preventive maintenance program aligned to manufacturer specifications and actual duty cycle data. Implemented a parts pre-positioning strategy to reduce emergency procurement lead times.
Results
- Unplanned failures for one product line reduced from >1200 hours/month to <400/month in 90 days
- Fleet availability improved from 43.3% to 85.9%
- Increased compliance of planned maintenance by 85%