Revamped a Maintenance Ticketing System & KPIs Tracked

A tier-one automotive supplier was plagued by maintenance inefficiencies that led to frequent equipment breakdowns, disrupting production and causing prolonged repair times. These challenges were further exacerbated by the lack of a cohesive and well-structured maintenance work order system, making it difficult to prioritize and track tasks effectively. As a result, operational efficiency suffered, and unplanned downtime became a persistent issue, negatively impacting overall plant performance and productivity.

The HPS team embarked on a deep dive into five years of historical maintenance work order data to uncover critical areas for improvement. By leveraging these insights, the team implemented a streamlined maintenance ticketing system designed to enhance transparency and operational control.

This system introduced new Key Performance Indicators, such as tracking mean time between failures, personnel response times, recurring machine issues, and machine-specific downtime, enabling a robust framework for continuous monitoring and improvement.

With the implementation of a new ticketing system, the client gained real-time visibility into equipment health and historical trends. This allowed them to proactively address issues before they escalated into major failures.

HPS didn’t just introduce tools—Through targeted training and guidance, a culture of proactive maintenance was created, ensuring the organization could sustain improvements and drive long-term operational efficiency.

• 26% Decrease in monthly equipment breakdown hours
• 6% Increase in parts-per-hour plant wide
• 0.5% Increase in OEE across all machines