Plant-Wide Facility Operations for an Auto Components Maker

The Challenge

An auto components manufacturer running a high-throughput plant was managing facility operations on a reactive footing. Equipment maintenance happened only after a breakdown, housekeeping crews worked without a shift-level plan, and waste streams from the production floor were handled inconsistently — leaving compliance gaps and clutter that slowed line changeovers.

The result was frequent unplanned downtime that disrupted production schedules and pushed up cost per unit. Plant leadership needed a single partner who could shift the operation from firefighting to a disciplined, preventive routine without interrupting output.

Our Approach

Innov mobilised an integrated plant FM team built around the rhythm of a three-shift manufacturing operation. The transition was phased line by line so production targets were never put at risk.

• Introduced a preventive technical maintenance programme with scheduled inspections, condition checks, and a planned-vs-breakdown work order log for every critical asset.
• Deployed industrial-grade housekeeping crews across all three shifts, with machine-side cleaning routines tied to changeover windows.
• Set up structured waste management — segregation, labelled storage, and tracked disposal of scrap, oils, and process waste in line with statutory norms.
• Established a unified shift handover and a monthly performance dashboard covering uptime, maintenance compliance, and housekeeping audits.

The Results

Within two quarters, the plant moved from reactive repairs to a predominantly planned maintenance regime. Unplanned downtime fell by 22%, equipment uptime climbed to 99.5%, and line changeovers became faster as floors stayed clear and waste was cleared on schedule.

With consistent operations across every shift and a clear reporting line, the plant's leadership could plan production with confidence — and Innov absorbed seasonal volume peaks without any drop in maintenance or housekeeping standards.