Increased revenue by 150% for a large industrial mechanic shop

The challenge

Our client operated a large industrial mechanic shop that serviced equipment that was critical to their customers' operations. Maintenance turnaround time was a critical requirement as it directly impacted their equipment downtime and bottom-line financial performance. When we started working with their team, their average job turnaround time was 3 weeks and they were regularly turning away customers due to limited capacity.

Our approach

We worked with the client to help them better understand and improve their job intake, inspection, maintenance planning, and mechanic scheduling processes. We identified root causes that increased job turnaround time and reduced work throughput. Through facilitated sessions we created pragmatic, tactical changes to their process that had tangible on-the-floor improvements.

Results delivered

The initiative achieved measurable and lasting impact:

• Reduced job turnaround time by 85% (from 21 day average to 3.2 day average)

• Increased job throughput resulting in a 150% increase in revenue without increasing overhead (i.e., without adding mechanics)

• Improved customer service by creating a consistent communication cadence, eliminating surprises and reducing the number of frustrated customers

These results have been sustained for two years since the onset of the project.

Why it worked

Solve’s success stemmed from our ability to deliver where others stall. Rather than relying on proprietary frameworks, we applied road-tested tools and a pragmatic approach tailored to the client’s environment. The engagement was led by senior consultants who stayed on the engagement from planning to execution, ensuring continuity, credibility, and results.