Case Study: Heavy Machine Manufacturer reduces maintenance costs with ARMS Reliability

Heavy Machine Manufacturer Maintenance Strategy Optimization Project

Heavy Machine Manufacturer, a manufacturer of dump trucks for the mining industry, was facing excessive maintenance costs and frequent production disruptions caused by recurring failures of its submerged arc welding machine. The company engaged ARMS Reliability to assess the problem and support a maintenance strategy optimization effort using reliability-centered maintenance (RCM) and FMECA analysis.

ARMS Reliability built a reliability simulation model to evaluate maintenance scenarios, identify dominant failure modes, and quantify hidden costs such as lost production, scrap, and quality issues. The study produced an optimized maintenance plan predicted to cut costs by $139,886 per year, or 64% versus current practice, and revealed welding tip damage as the biggest lifetime cost driver.