When an international beverage manufacturing facility faced a sudden, critical maintenance gap, we stepped in and helped decrease its high maintenance backlog. The facility located in North Texas produces beers and adult beverages, and they needed support to prepare for their peak season.
Client
Major International Beverage Manufacturer
Timeline
February to May 2024
Duration
4 months
Scope
Fully managed maintenance program
The Challenge
Our client’s facility operates 32 maintenance positions on rotating shifts to maintain 24/7 equipment coverage. A sudden operational disruption made the maintenance team unavailable. With the planning, scheduling and supervisory leadership also temporarily away from operations unavailable, the clock started ticking.
At the time, their maintenance backlog had grown to approximately six weeks, with roughly 200 hours of emergency work outstanding across the facility’s ammonia refrigeration unit, brewery cellar and can manufacturing lines. Our client needed a partner who could step in quickly, take ownership of the program and maintain full operational continuity.
Services Delivered
Our Approach
Our team of technicians reviewed the client’s full maintenance backlog and assessed their immediate operational needs. Rather than matching the facility’s existing headcount, we adjusted to fit the work required and deployed 10 technicians to cover a program built around 32 positions.
With maintenance leadership unavailable, our technicians stepped into planning, scheduling and supervisory roles from day one and provided millwright labor support. We learned the client’s SAP system on-site in a compressed timeframe to ensure uninterrupted operations. From intake to execution, we operated as a full program owner and helped decrease our client’s maintenance backlog by 90%.