Equipment Reliability & Condition – Case Studies

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FMCG / Food Processing – Preventive Maintenance & Line Efficiency

Client Background: A major food packaging unit was facing frequent production stoppages due to inconsistent maintenance practices and high changeover times.

Challenge:

  • Unplanned breakdowns leading to 15–20% loss in output.
  • No defined MTTR / MTBF monitoring.
  • Inconsistent spare part tracking and machine lubrication schedules.

Sava Solutions Approach:

  • Implemented a preventive maintenance system linked to production hours.
  • Established reliability KPIs (MTTR / MTBF) and trained operators in autonomous maintenance.
  • Standardized spare part inventory across similar filling and sealing machines.

Outcome:

  • Downtime reduced by 38%
  • OEE improved from 65% to 80%
  • Enhanced consistency in product quality and audit readiness.
FMCG Preventive Maintenance

Engineering & Fabrication – Equipment Refurbishment and Painting

Client Background: A mid-size engineering fabrication unit had aging cranes, press machines, and furnaces showing oil leakage, rusting, and low energy efficiency.

Challenge:

  • Reduced mechanical performance and safety risks.
  • Poor equipment appearance impacting customer visits and ISO audits.

Sava Solutions Approach:

  • Conducted equipment condition evaluation and categorized assets into A/B/C health groups.
  • Planned a phased refurbishment program including degreasing, mechanical overhauls, and repainting with heat-resistant coatings.
  • Introduced a visual factory initiative aligning with 5S standards.

Outcome:

  • Extended equipment life by 3–5 years.
  • Improved audit scores and workplace aesthetics.
  • Energy savings of 10–12% due to improved mechanical efficiency.
Equipment Refurbishment

Pharma & Medical Devices – Critical Equipment Reliability

Client Background: A medical device cleanroom facility faced intermittent equipment failure in extrusion and injection molding lines.

Challenge:

  • High validation costs after each breakdown.
  • Cleanroom compliance risk due to oil leaks and temperature fluctuations.

Sava Solutions Approach:

  • Conducted root cause analysis (RCA) on major downtime contributors.
  • Implemented condition-based maintenance using vibration and temperature monitoring.
  • Refurbished hydraulic systems with FDA-compliant oil seals and repainted machinery with low-VOC coatings.

Outcome:

  • Reduced unplanned downtime by 45%.
  • Improved compliance readiness for audits (FDA, ISO 13485).
  • Enhanced overall factory uptime and stability.
Pharma Critical Equipment Reliability

Chemicals & Polymers – Spare Part Pooling for Like-to-Like Units

Client Background: Three polymer extrusion companies in the same region suffered frequent stoppages due to delays in imported spares and lack of shared stock.

Challenge:

  • Long lead times (8–10 weeks) for imported drives and heaters.
  • High working capital blocked in duplicated inventory across units.

Sava Solutions Approach:

  • Developed a shared spare part pooling model with defined contribution per member company.
  • Created a centralized database of critical spares (Siemens, Schneider, ABB).
  • Negotiated bulk procurement contracts with OEMs.

Outcome:

  • Inventory cost reduced by 25–30%.
  • Emergency downtime response improved to <24 hours.
  • Collaborative maintenance culture developed within the cluster.
Spare Part Pooling for Polymers

Automotive Components – Reliability Improvement through TPM & Analytics

Client Background: A tier-2 automotive supplier producing machined metal components needed higher uptime and lower rework rates.

Challenge:

  • Frequent minor stoppages not tracked systematically.
  • Maintenance team overloaded with reactive work.

Sava Solutions Approach:

  • Introduced Total Productive Maintenance (TPM) framework.
  • Integrated downtime capture with digital dashboards (MTBF/MTTR tracking).
  • Refurbished high-speed CNC machines and standardized preventive inspection sheets.

Outcome:

  • Breakdown frequency reduced by 50%.
  • Machine utilization improved by 12%.
  • Maintenance man-hours optimized by 18%.

Key Takeaways:

  • Cross-industry adaptability: tailored reliability programs for each sector.
  • Integrated expertise: from condition audits to spare part management.
  • Measurable outcomes: productivity, safety, and cost benefits.

Sava Solutions – Building High-Performance Manufacturing Ecosystems.

Automotive Reliability TPM Analytics

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