Case Studies....why do our programs work?

because we use kpi data and sustainable processes to eliminate reactive maintenance and time-based containment Pm's.  this reduces waste and requires fewer resources to keep your mro and non-core processes in control

How?  By measuring the KPI's that matter, taking timely corrective action based on the data, and measuring compliance to our control plans daily, we ensure your non-core processes stay in control.  We then use the data to identify and drive sustainable Continuous Improvement.  Check out some of the stories below that highlight where condition based management has resulted in significant and sustainable total process cost reduction.  

Part 1 - A story about an Engineering manager that was looking to move from a reactive culture to a condition based, data driven culture.  

Part 2 - How a defined system of implementation can help erase tribal knowledge and move to a KPI driven management strategy to drive improvement.

The distribution process

In this case study, we look at how process variability can impact cost.  Variability was built into the infra structure used to deliver coolant to the factory floor.  It had been this way for 20 years.  Using data to deliver the results we were after, this significant source of variability was 1st identified, then resolved and then validated to ensure its no longer the source of waste and wasteful activity.  

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A better product

Not all products are created equal, and price is not always the right indicator of quality.  In this case study, we used our Independent Fluid Evaluation Process to identify a product that would let this facility run longer between clean-outs and run at a lower concentration reducing charging costs and the continual top-up required to maintain target concentrations in a machining environment.

CI-214- Coolant Consumption Reduction (I
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how tightening the process controls, translates into cost savings and lower process risk

This is an excellent example of how improving the control of the KPI's that impact cost and performance can translate directly into reduced fluid consumption and lower waste generation.  This case study shows a dramatic reduction in fluid usage by improving the controls around the concentration management process.  

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relying on Tribal knowledge cost this plant thousands of dollars a year!

For years this company relied on the operators to determine when their fluids were no longer suitable for continued use.  this led to significant waste and hurt their OEE.  Moving to a data driven program, their cost per part manufactured dropped in half, increasing up time, and significantly reducing the volume of waste produced.

CI-216 - Eliminating Tribal Based PM's.p
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Managing contamination within acceptable limits reduces this plants waste costs by over 70%

For this re-manufacturing facility, contamination from grease and grime quickly overwhelmed their washers and wash chemistries.  Implementing active condition based management with an innovative on-site recycling solution had a dramatic impact on delivering consistent cleaning performance while significantly reducing costs.

CI-217 - Reducing total process cost whi
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sustainable corrective actions come from understanding the kpi's that impact your measureables

In this case study, our client was getting flagged for poor part cleanliness performance.  The knee jerk reaction is to raise concentrations or increase fluid change-out frequencies.  In this case we isolated the KPI that was driving the issue and put in the controls to manage it, reducing the total process cost while still minimizing risk of a re-occurrence.   

Part Cleanliness Process Capability
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The best of both worlds, focus plant resources on core operations by outsourcing mask cleaning, but keep it on-site to minimize costs, manage HS&E risk and improve availability

In an effort to minimize part quality issues resulting from paint over-spray on dirty part masks, this Parts Manufacturer decided to use a 3rd party service to clean their masks.  When cost and availability became prohibitive, they evaluated the feasibility of bringing the cleaning operation back on site.  after a detailed technical evaluation,. Zimmark provided a complete turn-key solution providing significant savings and risk mitigation to the client. 

Turn-Key On-site Mask Cleaning
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