$2M
in freed capacity
41%
reduction in machine malfunctions
18%
reduction in machine breakdowns
The Solution
Ashling Partners introduced the Maintenance Control Center, powered by Celonis, as a comprehensive answer to these challenges. This innovative application is an integral part of our core manufacturing command center and is built on Ashling’s lean analytical framework. Key elements of the solution included:
Active Monitoring & Strategic Clarity
Real-time monitoring delivers critical alerts on machine breakdowns and operator activities, while proactive notifications enable technicians to address high-risk issues before escalation.
Planning & Scheduling
Consolidated machine data streamlines maintenance scheduling. Predictive analytics forecast needs using historical downtime and activity trends, shifting maintenance from reactive to proactive.
Integrated Insights for Informed Decision-Making
Results & Benefits
The implementation of the Maintenance Control Center led to transformative outcomes:
-
Freed $2M in Capacity: Enhanced predictability and efficient scheduling unlocked previously under-utilized capacity.
- 41% Decrease in Machine Malfunctions: Improved monitoring and proactive maintenance strategies reduced malfunction incidents, translating to a 45% decrease in hours lost.
- 18% Decrease in Machine Breakdowns: By addressing potential issues before they escalated, machine breakdowns dropped significantly, with a corresponding 26% reduction in lost operational hours.
These improvements not only bolstered revenue and productivity but also enhanced product quality and vendor accountability—ultimately positioning the client for sustainable, long-term growth.
Looking Ahead
As manufacturers continue to navigate the digital transformation landscape, integrating real-time monitoring with predictive analytics is essential. Ashling Partners recommends that organizations:
- Leverage comprehensive command centers to unify maintenance data across systems
- Invest in proactive, data-driven maintenance strategies to optimize capacity and reduce downtime
- Utilize integrated insights to drive continuous improvement in operational performance
This case study underscores how a strategic pivot from reactive maintenance to a proactive, predictive model can fundamentally enhance operational efficiency. The Maintenance Control Center is not just a tool—it’s a platform for leaders in operations and finance to drive measurable improvements and secure a competitive edge in today’s fast-evolving manufacturing environment.
Technology Used
Enhance productivity, increase capacity and reduce maintenance costs with the Maintenance Control Center, powered by Celonis. Offering a comprehensive, system-agnostic solution designed for any industry that relies on machinery for production, it uses real-time data and analytics to monitor and control manufacturing processes. Get event and value-based monitoring of plant floor machine operations, alerts for line stoppages or break-fix activities, and predictive analytics to forecast maintenance needs and preempt critical incidents.
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