Challenge

A large manufacturing plant in the eastern United States covers hundreds of acres and produces a wide range of products. However, its aged HVAC equipment frequently broke down, resulting in significant downtime as well as thousands of hours in maintenance and repairs.

With plant production and budget at risk, the organization needed a new provider—one who could keep stakeholders informed, gain a deep understanding of the site and assets, respond quickly and effectively, get repairs right the first time, and deliver valuable expertise. The customer needed a partner who could become a trusted extension of their own team.

Solution

After assessing the plant’s needs and working with stakeholders to develop measurable KPIs, Johnson Controls and the manufacturer launched an Asset Lifecycle Management Program. This program was designed to restore the HVAC equipment to working order, and then ensure a programmatic response to operations and maintenance. The program requires expert coordination of people, processes and technology to deliver the customer’s specified outcomes.

Results

Johnson Controls helped the manufacturing plant achieve measurable success within six months.

• Uptime over 90%, improving estimated production output by a remarkable $40M

• 50% reduction in annual maintenance and repair hours, saving $773,280

• 100% on-time preventative maintenance, extending asset life

• Estimated $5M+ to bottom-line profitability