Industry: Precision Metal Fabrication
Facility Size: 85,000 sq. ft.
Employees: 120
Key Equipment: Press brakes, CNC machines, welding stations
⚠️ The Problem
The manufacturer struggled with rising unplanned downtime and inconsistent preventive maintenance. In-house technicians were overextended, leading to reactive repairs and missed PMs.
Equipment failures were increasing
Overtime labor costs were rising
Production deadlines were missed
No clear metrics or PM strategy
🛠️ The Solution: Bring in a Maintenance Consultant
TLX was brought in to evaluate and restructure the PM program. The client opted to outsource preventive maintenance under our consulting and execution model.
We implemented:
- A custom preventive maintenance schedule for each asset
- CMMS optimization with mobile checklists
- Clear KPIs tied to downtime, PM completion, and MTBF
- On-site PM execution by certified TLX technicians
📈 The Results (After 6 Months)
Metric Before > After Improvement
- Unplanned Downtime 28 hrs/month > 17.3 hrs/month ↓ 38%
- PM Compliance 46% > 97% ↑ 111%
- Equipment Availability 88% > 95% ↑ 7 pts
- Maintenance Labor Cost $12,000/mo > $8,500/mo ↓ 29%
💡 Key Takeaways
Hiring a maintenance consultant provides outside expertise to spot gaps in your strategy.
Outsourcing PM frees up internal teams to focus on repairs, production, and continuous improvement.
ROI is measurable—reduced downtime, lower costs, and improved asset reliability.
✅ Is It Time to Reevaluate Your PM Strategy?
If your internal team is too busy firefighting to focus on prevention, outsourcing your preventive maintenance may be the smartest, most cost-effective move you make this year.
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