The Challenge
What needed to change.
Frequent breakdowns of CNCs, presses, automated lines, test equipment, and production tooling were creating a cycle of disruption that threatened program commitments:
- Recurring production bottlenecks and cost overruns
- Growing schedule risk across programs
- Eroding customer confidence in delivery predictability
- Reactive maintenance culture with no early-warning capability
The Fulcrum Approach
How we solved it.
Fulcrum transformed the manufacturing floor through a combination of IoT-enabled monitoring, predictive analytics, and a reliability-centered maintenance culture.
- Installed IoT-enabled sensors on critical production equipment to capture vibration, temperature, and load cycle data
- Designed and rolled out a Condition-Based Maintenance (CBM+) framework triggered by equipment health data, not calendar schedules
- Developed a phased modernization plan for legacy equipment, prioritizing high-risk assets for digital retrofits including PLC upgrades
- Scheduled mid-life overhauls for other machines to steadily improve reliability without disrupting operations
- Trained operators and maintenance staff in reliability-centered maintenance, RCFA, and FRACAS practices
- Integrated maintenance planning into the production schedule using daily stand-ups and shared visual management tools
- Established reliability dashboards and KPIs shared with leadership, reinforcing accountability and continuous improvement
Impact Delivered
Results that matter.
Outcome
30% reduction in downtime
Outcome
Higher throughput and backlog recovery
Outcome
Lower maintenance costs and reduced expediting
Outcome
Improved supplier ratings and customer trust
The facility achieved resilient, predictable operations while reducing costs across the board.