PGT Industries Case Study
The True Cost of Maintenance
By Identifying “Bad Actors”
From 10% to 70%
PGT Industries Leverages eMaint CMMS to Understand the True Cost of Maintenance
PGT Industries is a leading manufacturer of custom aluminum, vinyl and impact resistant house windows, doors and porch enclosures. PGT Industries wanted a solution to help schedule preventive maintenance, track assets and inventory, and report on Key Performance Indicators (KPIs). Today, the company can measure the effectiveness of assets, and identify “bad actors” that are having the greatest impact on downtime and labour costs.
PGT Industries is a leading manufacturer of custom aluminum, vinyl and impact resistant house windows, doors and porch enclosures. In the company’s main plant, they have 28 production lines running 24/7 due to heightened demand for PGT Industries’ products. Dwayne Summers, Maintenance Manager for PGT Industries, has been with the company for a year and a half.
When PGT Industries outgrew their paper-based maintenance management method, they wanted a solution to help schedule preventive maintenance, track assets and inventory, and report on KPIs. When Summers tested the first CMMS the company selected, he found it did not fulfill many of their needs. In searching for a new solution, he selected eMaint based on its robust feature set and reporting capabilities at an affordable price.
Through a collaborative effort from eMaint’s Customer Success team, and PGT Industries’ maintenance team, Summers was able to import existing maintenance data while establishing assets and assigning them criticality rankings. To get comfortable with the system, the PGT Industries team initially focused on monitoring corrective maintenance, then moved to tracking and reporting downtime and costs by department, project, asset or individual.
By effectively tracking and reporting on maintenance data, Summers can measure the effectiveness of assets, and identify “bad actors” that are having the greatest impact on downtime and labour costs. The team can isolate problems, revitalise preventive maintenance scheduling and use data to drive repair vs. replace decisions.
This data also helps support staffing decisions and provides vital information on lost production issues, ultimately translating into loss of units vs. maintenance downtime. For example, with eMaint CMMS, the team can calculate that downtime of one hour can equate to a loss of 100 units. PGT Industries can also justify their maintenance staffing by tracking employee wrench time.
Prior to eMaint, the company maintained a ratio of 90% reactive to 10% preventive maintenance. Since implementing eMaint’s PM scheduling software, they have almost reversed these statistics, with a rate of 70% preventive and 30% corrective work orders monthly. The team also has increased visibility into spending and budgets by tracking labour charges to capital projects within eMaint. Summers has the ability to track and generate reports based on labour hours and costs by project.
- Ability to understand the true cost of maintenance by project, department, asset and individual
- Increased efficiency by identifying “bad actors”
- Justified staffing decisions by tracking employee wrench time
- Increased planned maintenance rates from 10% to 70%
- Improved visibility into actual vs. budgeted labor costs for capital improvement projects