Case study

PCC Structurals Goes Mobile and Simplifies Audits with eMaint

Customer Since: 2022 | Industry: Aerospace

Customer since 2022 5 min read

PCC Structurals streamlined its maintenance operations by transitioning to eMaint X5, gaining real-time asset visibility, automated data capture, and faster repair times across multiple sites.

Mobile app and asset QR codes for work requests significantly reduced response and repair times.
Eliminating paper records streamlined audits and improved data accessibility.
Simplified work hour tracking with eMaint mobile app improved labor oversight and enabling accurate maintenance cost analysis.

SUMMARY

PCC Structurals, a world leader in superalloy, aluminum, and titanium investment casting, upgraded its maintenance management system to eMaint X5 to streamline operations, improve asset tracking, and gain better insights into maintenance costs. Prior to implementing eMaint X5, PCC Structurals used two separate maintenance systems for PMs and work orders, relied on manual data entry from handheld tools, and used paper-based records, complicating audits and obscuring maintenance Key Performance Indicators (KPIs).

Since adopting eMaint X5, PCC Structurals has experienced significant improvements. Work orders are now streamlined with QR codes, enabling faster repair times and better communication. Technicians use the eMaint mobile app to access real-time asset data, track labor hours, and reduce troubleshooting time. Meter readings with Fluke handheld tools, uploaded from in the field, ensure accurate, reliable data. The switch to digital records and automated data collection has also made audits faster and more efficient, with simplified enterprise reporting providing clear, accessible maintenance data.

BACKGROUND

PCC Structurals is a world leader in superalloy, aluminum, and titanium investment casting. Headquartered in Portland, OR, PCC Structurals manufactures injection molding of wax and plastic, including parts found in most airplanes.

PCC Structurals transitioned to eMaint X5 to improve its asset management, gain greater insight into maintenance costs, and achieve quicker repair times.

CHALLENGES

Jeremy Dahl, Facilities and EHS Manager, explained the key challenges that led to transitioning to eMaint X5:

Two software systems and duplicate efforts: "Our old system consisted of two separate maintenance software programs, one that would track PMs and one that would track work orders. So, you had to go into two different programs," said Dahl. With a small team of just six electricians, six technicians, and four mechanics working across four sites, eliminating wasted time was critical.

Manual inputs from measurement devices: "Our old system didn't allow you to upload data from handheld devices," Dahl explained. Instead, technicians had to manually enter readings from calibration tools, which increased maintenance time and potentially decreased data entry accuracy.

Lack of visibility into maintenance costs: Paper records made it difficult to track how much time technicians spent on repairs and made it nearly impossible to monitor key metrics such as asset downtime.

Paper audit trails: Paper recordkeeping made preparing for audits challenging and time consuming. "We have ISO audits every two years," explained Dahl. "Previously, our calibration records were paper. Then we'd have to go find the person that had the paper and hope they remembered where the paper was," before they could pass the audit.

IMPLEMENTATION

Dahl first learned about eMaint X5 at Xcelerate, Fluke Reliability's annual maintenance and reliability conference. "The capabilities of X5 really piqued my interest when I was doing the basic training at the conference," said Dahl. "I saw how you could corral all your assets and how you can track the time spent working on machines along with the labor changes."

"The migration to eMaint X5 was great," he said. "I listed out our assets, I sent in a spreadsheet and like magic, there it was in X5! It was really easy to get there."

Next, Dahl and his team plan to integrate eMaint with their Ignition SCADA software to get real-time asset data and generate condition-based alarms and work orders. "eMaint already has the functionality and people have already figured out how to tie it to Ignition, so I don't have to worry about that either," said Dahl. "It's just a matter of saying 'go'."

RESULTS

Since migrating to eMaint X5, PCC Structurals has seen significant improvements across its plants.

Streamlined work orders and elimination of paper records: "For each asset, we've created QR codes," said Dahl. "So, when someone puts in a work order, they simply scan that QR code, that populates what the asset is, then they tell us the problem. Simple… To have those people that are witnessing the breakdown and put information in there, rather than play the telephone game to try to figure out what's wrong, has gotten us quicker response times and quicker repair times." Technicians use the eMaint mobile app to access the work order and maintenance history of each asset they're working on. With the touch of a button, they can access notes from previous technicians, work history, previous parts used for repairs, and other key information to save time troubleshooting.

Improved time tracking and costing: With the eMaint mobile app, technician time is easy to track. "We had no real oversight of what technicians were doing until we started using eMaint X5. And now we can see pretty much what technicians are doing all the time."

Clarity for accurate KPIs: Instead of estimating how long an asset was down and how long the technician worked on it, technicians can centralize their asset data with eMaint. "With eMaint, there's a stopwatch. When that work order comes in, that machine breaks down, you can start the clock. And when the technicians finish, they can stop that clock," explained Dahl. "So now you can start tracking real downtime and not just guessing."

Reliable, automated data capture from handheld tools: Handheld Fluke tools connect seamlessly with the eMaint mobile app, automating data capture with accuracy. "You're able to track all your data without having to wonder if someone entered it correctly, because they're simply pushing that button and taking the reading off of the device, versus typing something in," said Dahl. "It's more reliable data that we're getting."

Faster, smoother ISO audit process: With streamlined data capture from calibration tools along with detailed electronic maintenance records, the audit process is much smoother. Every piece of data is readily available for auditors with eMaint reporting, bringing clarity and speed to the audit process.

“Our biggest challenges have been getting rid of paper records, not having paper printouts of a PM schedule weekly. Now, it’s all right there.”

– Jeremy Dahl, Facilities and EHS Manager

“One of the big draws is being able to manage all the equipment in the remote site and the three buildings that are on this property, along with being able to manage the technicians. We had no real oversight of what they were doing until we started using eMaint. And now we can see pretty much what they’re doing all the time.”

– Jeremy Dahl, Facilities and EHS Manager

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