Amsted Automotive's Breakthrough in Manufacturing Efficiency
Amsted Automotive has reached an impressive milestone by achieving a mere 1% downtime across most of its 15 global manufacturing facilities. This accomplishment includes 12 locations within the U.S. and is indicative of the company's commitment to excellence in operational efficiency.
The journey towards this remarkable achievement began several years ago when Amsted Automotive launched a comprehensive initiative aimed at enhancing operational efficiency within its manufacturing sites. The main objectives were to minimize downtime and lower the overall costs associated with asset ownership through strategic predictive maintenance.
To accomplish this, the company utilized state-of-the-art real-time data analysis and artificial intelligence. By predicting potential equipment failures before they occur, Amsted could effectively manage maintenance schedules, thus reducing unexpected repairs and ensuring smoother operations.
Developing a Robust Maintenance Management Strategy
At the forefront of this strategy was Jason Hahn, the Global Reliability and Systems Manager at Amsted. He crafted a methodical plan that encompassed various stages including implementation, measurement, and analysis of maintenance practices. To facilitate this process, Hahn utilized eMaint software from Fluke Reliability, which operates as a Computerized Maintenance Management System (CMMS).
This software plays a pivotal role in optimizing maintenance operations and effectively managing the entire lifecycle of assets. eMaint supports tracking from the acquisition phase all the way to disposal, ensuring that performance metrics remain high throughout.
Enhancing Productivity Through Dashboards and Innovations
In addition to deploying eMaint, the adoption of the new processes included developing customized dashboards. These dashboards aligned the information needs of all maintenance departments, enabling timely accountability, shifts' transitions, and assisting in monthly KPI reviews. Each location utilized monthly scorecards to track progress, covering areas such as failure rates, predictive yields, and downtime reductions.
Simultaneously, Hahn established a centralized predictive maintenance program that includes diverse technologies like acoustic imaging for identifying air leaks, thermal imaging for detecting electrical issues in facilities, and vibration metering for monitoring the health of bearings and gearboxes.
Automation and Its Role in Operational Excellence
Through the employment of automation tools designed to streamline workflows, the team effectively reduced the number of keystrokes required by maintenance technicians. This included automating field population and facilitating email notifications regarding work order statuses. As a result, the team improved its speed and efficiency while also meeting waste reduction targets.
Hahn presented insights regarding the benefits of predictive maintenance and its role in Amsted's operational success at a notable conference. His experiences reflect the significant advancements the company has made toward redefining its maintenance strategies for a better operational future.
About Amsted Automotive
Amsted Automotive, formed in 2021, brought together Means Industries Inc., Transform Automotive, SMW Manufacturing, and Burgess-Norton Mfg. Co., Inc. to create a pioneering technology team. Together, they operate 21 facilities across North America, Europe, and Asia, effectively serving the automotive, off-highway, and mining sectors. The organization boasts a robust manufacturing footprint that produces over 100 million components and assemblies each year.
Amsted Automotive is dedicated to delivering precision products and propulsion systems that adapt to electrified, hybrid, and internal combustion engine platforms. Their integrated efforts play a crucial role in the development of global automatic transmissions that are manufactured across various regions.
Frequently Asked Questions
1. What achievement has Amsted Automotive recently accomplished?
Amsted Automotive has successfully reduced manufacturing downtime to just 1% at most of its global facilities, enhancing productivity and reliability.
2. How does predictive maintenance factor into Amsted's strategy?
Predictive maintenance is utilized to anticipate equipment failures, allowing Amsted to minimize downtime and enhance overall operational efficiency.
3. Who leads the reliability and systems management at Amsted Automotive?
Jason Hahn serves as Amsted's Global Reliability and Systems Manager, spearheading strategic initiatives for maintenance and operational excellence.
4. What technologies are being leveraged for maintenance innovation?
Technologies like acoustic imaging, thermal imaging, and vibration metering are implemented to enhance predictive maintenance programs.
5. Where does Amsted Automotive operate globally?
Amsted Automotive has a significant presence in North America, Europe, and Asia, operating 21 facilities worldwide.
