Reducing downtime by 3.2h per week in a foundry
We introduced a simple preventive maintenance schedule. Machines stopped failing at the worst moments for orders.
At Metal-Tech Odlewy, machines failed when orders were highest. We shortened downtime by 3.2h per week, which translated into real money and calmer nerves for the owner.
The challenge
The plant operated on three shifts, but the sand molding machine broke down an average of 4 times a month. Repairs took a long time because mechanics reacted only when something already broke. In July 2024, due to a sudden motor failure, the foundry lost 14 hours of work. This meant 47 unfinished pump body castings. Losses in material alone and overtime amounted to over 8,400 PLN in one weekend. No one knew when the next failure would occur, which paralyzed shipment planning.
Our approach
We sent two of our maintenance experts to the floor – Marek and Darek. For 11 days, they analyzed failure logs from the last 8 months. They talked to operators directly at the furnaces, not just with the manager in the office. We looked for the moment when bearings start to howl before they completely seize. It quickly came to light that the problem wasn't the age of the machines, but the lack of a simple lubrication and filter replacement plan on specific days. We count every penny, so we didn't propose expensive sensors, just specific procedures for people.
The solution
We introduced a paper control system that takes an operator exactly 6 minutes at the start of each shift. We didn't play with tablets because there's too much dust and high temperatures on the floor – a regular form on a clipboard works better. Additionally, we organized a cabinet in the workshop with a supply of 12 critical parts that previously took 3 days to arrive from a supplier. Now, replacing a small element is a matter of 15 minutes, not waiting for a courier for half a week.
Results
Downtime dropped drastically, and the company recovered time that previously slipped through its fingers. Floor specifics are clear: machines run more stably.
Timeline
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August 2024Technical audit of machines and interviews with shift operators.
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August 2024Analysis of failure history and spare parts costs.
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September 2024Implementation of 6-minute checklists and a service cabinet.
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September 2024Training mechanics on preventive maintenance.
"Initially, I thought the old machines were to blame and new ones were needed. Orzeł Strategii Group showed us that the lack of a plan was the culprit. Now the machines simply run, and we save on service."