Top Heavy Equipment Manufacturer Saves Over $10 Million in 2024

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

Maintenance Multicraft Technicians

High turnover rate

Internal maintenance team experienced challenges and retaining the technical talent needed for demands

Engineering Increase Uptime OEE

Declining asset availability

With past-due shipments increasing, the site needed a partner to drive uptime

Continuous Improvement Processes

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:

  • Industrial Technology
    Preventive maintenance program

    Developed to reduce unexpected breakdowns and prioritize proactive upkeep

  • Worker idea
    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

  • Maintenance Predictive Tech
    Planning & scheduling overhaul

    Streamlined maintenance processes and improved asset management for more efficient operations

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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.

Communication

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

Toolbox

Preventive maintenance (PM) optimization

Maintained a consistent 100% PM completion rate, enhancing uptime and equipment reliability

Engineering Boost Asset Reliability

Proactive cost management

Achieved $10.8 million in cost savings within 2024, driving exceptional results

HR Overcome Turnover

Improved machine availability

Increased monthly machine hours by 54%, significantly improving production capacity

HR Benefit Training

Skilled workforce development

Focused on training and retention to maintain high-quality, consistent service

Improve equipment reliability

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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.”
– Pontiac, IL Facilities Engineering Manager | Leading heavy equipment manufactuer

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.

cnc machines

Heavy equipment manufacturer

With an extensive customer base production uptime is crucial

Industrial maintenance

150+ facilities globally

The manufacturer’s large operations require consistent, reliable partnerships

Worker idea

Leading in innovation

The partnership sustains high-tech equipment through proactive maintenance

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