Case Study: Gypsum Company achieves record uptime and output with Advanced Technology Services factory maintenance solution

ATS Nails Drywall Factory Maintenance Issues, Turns Texas Plant into Top Producer

Gypsum Company’s Texas drywall plant was struggling with unreliable production in a 24/7 continuous operation. Frequent downtime, weak preventive maintenance practices, and poor spare parts planning left the facility near the bottom of the company’s U.S. manufacturing rankings and forced orders to other plants. Advanced Technology Services (ATS) was brought in to provide factory maintenance and reliability services.

ATS implemented a structured maintenance program tied to the plant’s CMMS, adding scheduled preventive maintenance, better planning, and trained technicians assigned by priority. As a result, maintenance shutdowns were reduced from weekly to as infrequently as once a month, board line availability improved 6%, utilization improved 26%, output increased 21%, and scheduled run-hours increased 15%. The plant also moved to number one in OEE across the company’s gypsum operations, and ATS earned a long-term contract extension.