As a service champion, we are passionate about our customers. Our goal is to create a leading edge for our customers. A unique combination of customized services and highly qualified teams makes us the preferred partner of the manufacturing industry all over the world and in various industries. With the following references, you can get a small overview of our wide-ranged services.
Case Studies
Content
Content
- Production Equipment Maintenance
- Complex Service Agreement
- Production Equipment Maintenance
- Paint Shop Technical Cleaning
- Buffering Conveyor System
- Equipment Install
- Safety System Replacement
- Paintshop Management and Technical Cleaning
- Engine Line Install
- MRO Stores Management
- Contact
- Service Inquiry
- Job Inquiry
Production Equipment Maintenance
Key Facts
The customer: a major white good manufacturer
Start of contract: 2018
Contract duration: 3 years
Size of plant: 2.000.000 m²
Service type: Production Equipment Maintenance, Technical Cleaning
Challenges
- Little asset history/use of CMMS
- Low number of processes for preventive maintenance and asset reliability
- Low OEE in key value streams
Tools & Procedures
Production Equipment Maintenance
Planned Jobs and Project Completion Maintenance
Equipment Cleaning
Management of Technical Training Lab and Program
Development of Technical Training Course Material
Results / Added Value
- Strong focus on developing new preventive maintenance tasks and improving existing PMs to reduce downtime of critical assets
- Developed a 200-point technical assessment to develop customized development plans for all client and Leadec team members
Complex Service Agreement
Key Facts
The customer: a major automobile manufacturer
Start of contract: 2019
Contract duration: 3 years
Size of plant: 700.000 m²
Service type: Facility Management, Technical Cleaning, Housekeeping, Production Support
Challenges
Diversity of service offering to support Assembly, Stamping, Body, Global Propulsion and Suppliers
- increased customer GMS and scorecard requirements with reduced resources
Tools & Procedures
Facilities & production support maintenance
Housekeeping
Technical cleaning of weld cells and plant equipment
Cardboard and other production support
Grounds management
Results / Added Value
Leadec Spring Hill consistently performs among the top SA providers for OEM.
Excellent partnership and service delivery creating a sustainable business relationship.
Customer survey score of 93% for 2020.
Strong safety culture with a .67 recordable rate for 2020.
Diverse and skilled management team capable of service expansion and delivery.
Production Equipment Maintenance
Key Facts
The customer: a major manufacturer for airplanes
Start of contract: 2016
Contract duration: 5 years
Size of plant: 140.000 m²
Service type: Production Equipment Maintenance
Challenges
High complex production
Complex technical and IT-interfaces
Technical availability of the equipment by 98 % is required
Tools & Procedures
Production Equipment Maintenance
Planned Jobs and Project Completion Maintenance
Management of Tool Control Program for Facilities and Asset Management
Maintenance of Ground Support Equipment
Manage Production Equipment Work Order
Results / Added Value
Strong focus on contract based key performance indicators (reaction time, reduction of downtime, technical availability)
Successful collaboration with suppliers in the field of warranty management
Development of a machine history that enabling optimization of maintenance- & production processes
Significant annual savings
Paint Shop Technical Cleaning
Key Facts
The customer: a major truck manufacturer
Start of contract: 1995
Contract duration: annual
Size of plant: 47.000 m²
Service type: Technical Cleaning
Challenges
- High requirements in technology and quality
Tools & Procedures
MRO storeroom management
Accurately process spare parts within the CMMS (Maintimizer & SAP) for future availibility
Water reclamation management of Paint booths
Chemical Technician is responsible for monitoring and adjusting chemicals to ensure that water pH levels are within range
Results / Added Value
Customer received an internal award; their internal audit yielded the best scores this site has seen in over 30 year
Safety Oriented; 525 days and counting of operation with zero recordable injuries
Excellent customer service; Customer has recognized Leadec's performance
Buffering Conveyor System
The assignment
Design and build buffering conveyor system for vehicle bodies prior to entrance into paint.
The challenges
- Limited space required ceiling suspended mezzanine to be designed and fabricated so equipment could be installed over existing welding equipment.
- Building trusses were initially found to be inadequate to support mezzanine, therefore, ceiling reinforcement was necessary.
- All work was to be completed during shutdowns and off hours.
The process
- Step 1: Reinforce roof trusses to support mezzanine.
- Step 2: Hanging the mezzanine supports designed by Leadec. Note: Roller beds lifted to sections as they are installed.
- Step 3: Installing mezzanine sections designed by Leadec. Note: Installed and welded.
- Step 4: All conveyor design completed with Inventor
- Step 5: Conveyor assembled and kitted at shop. Note: Kitting, prewired and tested in shop to reduce installation time.
- Step 6: PLC design and fabrication completed. Note: Kitting, prewired and tested in shop to reduce installation time.
- Step 7: Installed and commissioned on site.
Equipment Install
The assignment
- Equipment install for OEM: tallapoosa, GA
- Overall disciplines: engineering, mechanical, electrical, project management
- Engineer, fabricate + installation for overhead mezzanines
- Install of the customer supplied transmission line equipment
Scope of services
Greenfield project consisting of engineeing, fabrication, and installation of overhead mezzanines, cages, safety railing and electrical and mechanical installation of Transmission Line Equipment supplied by OEM.
Work performed
- (49) Tooling Stations
- (35) Conveyor Turntables
- (8) Elevators
- (1800 LF) Conveyor
- (3500 SF) Mezzanine
Safety System Replacement
The assignment
The manufacturer of the safety system obsoleted the safety processor, IO and safety bus system. The customer, supported by Leadec, developed a more robust and supportable safety system utilizing current state of the art safety products.
Leadec equipment installations
- 28 Guardlogix processors
- 28 Startic S700 Ethernet switches
- All new AB safety rated inputs/outputs
- Cable tray and panel modification
The challenge
Modify during shutdowns and weekends to minimize production interruptions.
The outcome
Leadec was responsible for:
- Providing new safety layout
- Removing existing hardware
- Pre-programming and installing new IO
- Modified drawing and redesigned network communications
Paintshop Management and Technical Cleaning
The assignment
- Complete management of 6 paint lines
- 1,600 Vehicles per day
- Skip cleaning, deep cleaning
- Skids, grates and fixtures removed, staged and reinstalled by Leadec
The customer
Large automotive OEM
The scope
- 5 Wet booths
- 1 Dry booth + 5 zones
- 8 Years on site
The outcome
- The only supplier recognized in 2016
- Highest first-run rate in company: Over 99.0%
- Net Promoter Score (NPS): 9.5/10
- 6% Cost savings per year
Engine Line Install
The assignment
Greenfield installation of customer equipment into AE facility.
The challenges
- Piston line
- Head line A (DI)
- Head line B (over/under conveyor)
- Block line A + B
- Main line A-D
- 8 Mezzanines
- 16 Elevators
- Approximately 100 robots
- 86 Automatic stations
- 1 Nut runner to be located from Plant 2
MRO Stores Management
Key Facts
The customer: a major automobile manufacturer
Start of contract: 2018
Contract duration: 3 years
Size of plant: 140000 m²
Service type: MRO
Challenges
- Greenfield implementation of spares storage solution and spares management process infrastructure
- Thousands of unidentified and uncatalogued parts as part of line builder initial spares packages
- Inadequate customer process for assigning unique part IDs (item #s) resulted in many duplicate IDs for same part
Tools & Procedures
- MRO storeroom management
- Accurately process spare parts within the CMMS (Maximo) for future availibility
- Fulfill and deliver material requests pertaining to work orders and consumables to specific drop points
- Methodically store parts to decrease downtime
- Collaborate with various entities to reduce lead times and ensure superb part / material availability
Results / Added Value
- Excellent customer service: Conduct weekly cycle counts to ensure storeroom accuracy; finished 2019 with a 99.6% accuracy rating
- Strong focus on a culture of safety; 966 days of operation with ZERO recordable injuries
- Identified and scrubbed 241 duplicate parts resulting in significant cost savings/avoidance
- Motivated to see our customer succeed in SC; significant annual cost savings recognized by the customer
Additional Information
- Manage the warranty and return program for all maintenance parts
- The team is comprised of: Material Specialist (3), Procurement Liaison (1), Shipping Clerk (1), and (1) Facility Manager
- Distribute all team-wear of the customer
- Complete weekly stock-out reports to identify and reorder items as needed
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