The Challenge
The plant was facing frequent unplanned shutdowns—on average 8 breakdowns per month—due to recurring failures in hydraulic presses and pneumatic assembly stations. Maintenance costs were soaring, and line supervisors struggled to keep uptime above 75%, leading to missed delivery targets and strained client relationships.
Our Approach
- In‑Depth System Audit
- Performed a full audit of all hydraulic and pneumatic circuits, identifying pressure drops, seal wear, and sub‑optimal valve configurations.
- Mapped existing Zero Balancer setups and torque tool calibration records to pinpoint weak spots.
- Custom Circuit Redesign
- Redesigned critical hydraulic circuits with precision flow controls and fail‑safe valves to prevent pressure surges.
- Upgraded pneumatic layouts—re‑routing air lines, adding dedicated moisture filters, and balancing actuators for smoother operation.
- Permanent Solutions & Calibration
- Overhauled Zero Balancers (manipulators) and pneumatic nut runners with best‑in‑class pre‑torque and oil‑pulse controls.
- Standardized calibration procedures for impact wrenches across all brands, ensuring consistent torque application.
- Hands‑On Training & Lean Implementation
- Trained a team of 50+ maintenance technicians in Poka‑Yoke, Kaizen, 5S, TPM, and autonomous maintenance methods.
- Introduced targeted maintenance case studies and machine‑breakdown reduction strategies under a Lean framework.
The Results
- Uptime Boost: Production line availability surged from 75% to 95%, translating to 120+ additional operating hours per month.
- Cost Savings: Maintenance expenditures dropped by 30%, saving roughly ₹2 million annually.
- Zero Recurrence: Hydraulic and pneumatic failures on redesigned circuits fell to zero over a continuous 3‑month monitoring period.
- Empowered Workforce: Technician productivity increased by 40%—team members now diagnose and resolve issues on the spot, without external support.
" Write a quote here from one of your customers. Quotes are a great way to build confidence in your products or services. "
--Maintenance Head...