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Embedding Preventative Maintenance to Restore Operational Performance
Background:
A Tier 1 automotive supplier faced urgent operational breakdowns and asset deterioration. With key customer deadlines at risk, the company required a full-scale turnaround to stabilize operations and restore confidence.Critical Issues:
- Persistent equipment failures and low operational efficiency
- Deteriorating assets creating quality risks
- Inactive preventative maintenance systems
- Imminent deadlines with limited internal support capacity
Approach:
Crossover mobilized an on-site team, scaling from 5 to 45 experts over a six-month period. We executed 24/7 operational coverage, stabilized performance, and built a sustainable preventative maintenance program embedded into daily operations.Key Actions:
- Delivered 24/7 maintenance operations to restore equipment uptime
- Reinstated quality control and implemented robust detection systems
- Developed standard work for preventative maintenance tasks
- Assigned specialists to drive throughput improvements
- Upgraded critical assets and implemented robot modifications with traceability
- Delivered a structured sustainability roadmap
Results:
- Restored production flow and stabilized key processes
- Embedded preventative maintenance as a core operating discipline
- Rebuilt internal capability, improved uptime, and re-established OEM confidence
By the Numbers
+42%
increase in efficiency (from 18% to 60%)
0
daily machine breakdowns (down from 4–5)
6 months
from deployment to full recovery