Case Study: Luxury Automaker’s Assembly Plant achieves 22% downtime reduction with Advanced Technology Services

ATS Puts Luxury Automaker’s Assembly Plant on the Road to Greater Productivity With 22% Downtime Reduction

Luxury Automaker’s Assembly Plant partnered with Advanced Technology Services (ATS) to address costly conveyor downtime at its North American vehicle assembly facility. The plant relied on a complex overhead carrier system to move chassis, engines, doors, and other components through final assembly, and production line reliability issues were sometimes costing as much as $16,000 per minute.

Advanced Technology Services implemented a preventive maintenance and continuous improvement program tailored to the automaker’s culture, technology, and scheduling processes, including advanced training for ATS staff and performance tracking across quality, safety, scheduling, KPIs, and training. The result was a 22% reduction in average weekly downtime for carriers and trim lines and a 29% drop in final carrier downtime, delivering an estimated $12 million in cost savings/avoidance over six months.