Electronics Manufacturing Scale-Up
Plant output doubled over 5 years at a high-precision electronics manufacturing site in Hungary. Through a structured Partner engagement, Propelance deployed OEE optimization, machine criticality analysis, CI teams, and a harmonized reliability maintenance framework — simultaneously improving technical availability by 30% and reducing corrective maintenance duration by 90%.
- Client
- Global Leader
- Location
- Hungary
- Duration
- Partner engagement
- Industry
- High-Precision Manufacturing
- 01
Customer commitments at risk. Market demand exceeded plant capacity and OTD targets were slipping — with direct revenue exposure on open contracts.
- 02
The industry demands high precision and ultra-high-speed motion — any unplanned downtime directly impacts throughput and margins.
- 03
Full order books led to preventive maintenance being deprioritized, triggering a decline in technical availability and a negative spiral of constant reactive firefighting.
- 01
OEE measurement system assessed and optimized to establish a reliable performance baseline across the plant.
- 02
Machine criticality analysis identified highest-priority assets where maintenance investment would yield the greatest uptime gains.
- 03
Continuous Improvement (CI) teams established to drive bottom-up improvements and embed operational excellence culture.
- 04
Root Cause Analysis (RCA) process and database implemented to systematically eliminate recurring breakdowns.
- 05
Preventive Maintenance (PM) plans redesigned using FMEA to target specific failure modes.
- 06
All initiatives integrated into a harmonized Reliability Maintenance framework for sustainable, scalable results.
- 01
Plant output doubled over a 5-year period — meeting extreme demand without proportional capacity investment.
- 02
30% technical availability improvement in the critical 90–100% operating range — recovering production hours during the plant's most valuable operating windows.
- 03
Corrective maintenance duration on the most critical machine family decreased by 90%, dramatically reducing unplanned downtime.
Plant output doubled over 5 years.
Improvement in the 90–100% range.
Corrective maintenance on critical machines.
Plant Output Growth Over 5 Years
A steady, linear climb year over year — from the baseline production level to plant output doubled over 5 years. This growth came from investment in maintenance excellence, not from installing new production lines.
The conventional assumption — that increasing output requires deprioritising maintenance — was the root cause of the decline.
By inverting it and investing in reliability first, the plant achieved output growth as a consequence of maintenance excellence, not despite it.
This pattern has been replicated across Propelance's electronics, food & beverage, and metals engagements — demonstrating that in high-precision manufacturing, the fastest path to capacity runs through the maintenance function.
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