The Cardinal Glass plant in Buford, Georgia has 100 assets that must be managed by the maintenance
team. Cardinal Glass, which was founded in 1962, has 4,500 employees in 28 locations and produces
residential glass that is energy efficient and designed to last a lifetime. In 2008, maintenance
management identified several key performance indicators (KPIs) that were showing signs of distress:

  • Downtime was running at 15%
  • Maintenance management was ad-hoc (a “run to failure culture was the norm), and
  • Downtime reports generated by production were not shared with the maintenance team

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Working with MP2, a computerized maintenance management software (CMMS) system, employed at
a sister division, the maintenance team was able to produce limited initial benefits: reduced downtime
and better scheduling and planning, but these were eventually tempered by the system’s inflexibility
and lack of provider support. Specifically, the system couldn’t support data reporting in the format the
team needed and without detailed historical data, it became impossible to analyze or identify trends
crucial to synthesizing the maintenance and production teams’ efforts.

After 15 months of substandard improvement, Cardinal Glass decided to work with eMaint (which
also provides CMMS solutions) to migrate their data to a more cost-effective, web-based system. The
eMaint MP2 converter efficiently and effectively migrated Cardinal’s data (assets, parts, PMs, work
history) into their X3 system and the team began to see positive results:

  • Easy labor tracking
  • Multiple preventive maintenance (PM) functionality:
    • Checklists (including daily inspections, work requests, repair orders and walk-throughs)
    • Inventory tracking of spare parts
    • Asset depreciation and maintenance costs
  • Planned activity and work status reports
  • Project planning

These and other functionalities (not the least of which was greater provider support) enabled Cardinal
Glass to reduce downtime from 15% in 2008 to 0.8% in 2011 (a 95% reduction), and consequently
enjoy significant cost savings. By reducing downtime, Cardinal has also been able to reduce production
shifts to four ten-hour shifts representing a meaningful reduction in labor hours by 43% and increase
their average daily production by over 40% from 2008 to 2011. These value-added benefits resulted in
Cardinal CG operating at a 45% profit after several consecutive unprofitable years.

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Dana Madama is the Online Marketing Manager at eMaint Enterprises, located in Marlton, NJ, which provides CMMS and EAM solutions for all of your maintenance and asset management needs.