Top Heavy Equipment Manufacturer Saves Over $10 Million in 2024
Strong foundations build path to operational excellence
Paving the way
In 2017, a leading heavy equipment manufacturer’s Pontiac, IL site faced significant challenges with inconsistent staffing, maintenance execution concerns, and rising past-due shipments. The need for a reliable, long-term maintenance solution was critical to sustain production efficiency and meet growing demand. The manufacturer partnered with Advanced Technology Services, Inc. (ATS) to step in with a comprehensive maintenance program, transforming the site into a model of operational excellence.
Increase in machine hours
Significantly improving production capacity
PM completion rate
Enhancing uptime and equipment reliability through consistent proactive activities
Year-to-date cost savings
Achieving bottom-line results across operations
Challenges bulldozing productivity
High turnover rate
Internal maintenance team experienced challenges and retaining the technical talent needed for demands
Declining asset availability
With past-due shipments increasing, the site needed a partner to drive uptime
Low productivity
Below optimal equipment productivity levels caused tension between departments
Setting the foundation: 2017 – 2021
To address the plant’s immediate concerns, ATS deployed on-site leadership and multi-craft maintenance technicians to run the facility’s maintenance operations. The team quickly shifted the approach from reactive to proactive maintenance by implementing several strategic initiatives:
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Preventive maintenance program
Developed to reduce unexpected breakdowns and prioritize proactive upkeep
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Introduction of reliability team
Focused on Reliability-Centered Maintenance (RCM) and Failure Mode and Effects Analysis (FMEA) to identify and address potential issues before they occur
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Planning & scheduling overhaul
Streamlined maintenance processes and improved asset management for more efficient operations
Breaking new grounds: 2022 – Now
With a strong focus on culture, safety and reliability, ATS implemented programs to enhance operational efficiencies and increase throughput for the site.
Machine health monitoring
A pilot program in early 2022 achieved a 4.2x ROI in just 90 days, leading to broader expansion and reduced unplanned downtime
Preventive maintenance (PM) optimization
Maintained a consistent 100% PM completion rate, enhancing uptime and equipment reliability
Proactive cost management
Achieved $10.8 million in cost savings within 2024, driving exceptional results
Improved machine availability
Increased monthly machine hours by 54%, significantly improving production capacity
Skilled workforce development
Focused on training and retention to maintain high-quality, consistent service
Improve equipment reliability
Strategic shifts drive long-term success
The success at the Pontiac, IL site serves as a benchmark for future partnership projects, with plans to expand similar models across other locations. By setting new standards for comprehensive maintenance, ATS has proven the value of a strategic, reliability-driven partner.
“ATS has been a game-changer for us, ensuring our equipment stays reliable and ready to meet production demands. Their proactive approach and skilled support have made a real impact on our uptime and overall efficiency.”
About the partnership
This global leader in heavy equipment manufacturing has cultivated a long-standing partnership with ATS, working together over the years to drive innovation, boost productivity, and achieve significant cost savings.
Heavy equipment manufacturer
With an extensive customer base production uptime is crucial
150+ facilities globally
The manufacturer’s large operations require consistent, reliable partnerships
Leading in innovation
The partnership sustains high-tech equipment through proactive maintenance