Now the Fluke team wants to help more Amsted maintenance teams deliver greater reliability and operational efficiency, reducing costs and increasing productivity.

We’re your partner for global transformation. Here’s how it works:

Experience. Our team has already worked closely with Amsted worksites, building the customized analytic tools needed to keep critical assets performing at their peak. We have the requisite expertise to deliver results right away.

Planning. Fluke is a recognized leader in planning across multiple worksites. Our software, tools, and team of experts all work together to put you on the path to achieving your maintenance and reliability goals, now and into the future.

Results. We are serious about maximizing your software return on investment, both in the short and long term. We’ll guide you through your connected reliability journey, helping you to meet your most ambitious targets.

Amsted Automotive is a global manufacturer of components for passenger and commercial vehicles. With over 2,000 employees located in facilities around the world, Amsted Automotive produces more than 200 million components every year.

Amsted manufacturing facilities rely on critical assets like hydraulic and mechanical presses, lathes, and mills running smoothly to meet production goals. Many sites rely on eMaint CMMS & EAM and a range of Fluke’s condition monitoring tools to implement a proactive maintenance approach, resulting in significant cost savings and a major reduction in downtime.

CMMS adoption was a significant challenge at the outset. Metrics at most of the facilities looked great on the surface – but data analysis with eMaint revealed a more complicated story. Hahn discovered PM completion rates were artificially high because PMs weren’t properly entered into the system. MRO teams weren’t creating work orders for most of the tasks they carried out. When they did generate work orders, they lacked detail. PM schedules weren’t optimized or accurately tracked.

The lack of data from work orders, PMs, and asset health monitoring meant that it was impossible to conduct meaningful failure analysis. The plants were all stuck in firefighting mode, which created operational waste and uncertainty. Decision makers lacked the tools and metrics they needed to do their best work.

Jason Hahn is the Global Reliability and Process Manager for Amsted Automotive. His mission, as he defines it, is to “build the path” for maintenance standardization across the 15 manufacturing facilities he manages in North America. A priority for Hahn is guiding Amsted’s facilities out of reactive maintenance mode and transitioning them to a data-driven predictive maintenance strategy.

That entails gathering and analyzing data, building an effective preventive maintenance (PM) structure, tracking spare parts inventory, and monitoring asset health. All those pieces come together with eMaint. As Hahn puts it, “The eMaint partnership is really important, because it’s the fundamentals behind most of what I do.”

With that in mind, Hahn dramatically expanded Amsted Automotive’s use of eMaint. By globalizing the adoption of eMaint, he and his teams acquired the data and analytics they needed to increase operational efficiency and reduce downtime.

Hahn’s goal was to achieve global digital transformation with eMaint so that his teams could use CMMS to build a standardized predictive maintenance strategy. Since CMMS adoption had been a challenge in the past, he decided to leverage eMaint automation and reporting capabilities to drive his teams to full implementation.

Tracking & Streamlining Implementation

Hahn used eMaint to create and track a set of metrics to monitor have successfully each facility was adopting CMMS. Some of the metrics he created and tracked include:

• Daily number of work orders entered
• Rate of PM completion vs. overall PM counts
• PMs with assignments
• Spares added to eMaint
• Asset labeling

eMaint customization was key to making this all happen, Hahn says. “I can’t move the needle without customization.” eMaint ease of use allowed him to create exactly the metrics he needed to drive change in his organization.

Automating Processes

eMaint automation features allowed Hahn and his team to automate workflows – like PM due date calculations, downtime calculation, and scheduling. The automation resulted in greater speed, efficiency, and a reduction in operational waste.

Most of the time, Hahn was able to create the customized metrics and workflows on his own. When he needed to design something a little more complex, he called on the eMaint customer service team. “Fluke helped me through,” Hahn says.

Training and Ongoing Education

Hahn also leveraged eMaint ongoing education and training resources to get his teams up to speed with the new tools. eMaint University provides on-demand training for new and existing staff. Amsted Automotive frequently onboards new technicians, and thanks to eMaint University’s personalization options, it’s easy to ensure they all receive the training they need to do their job correctly.

Data collection

Amsted uses a range of Fluke condition monitoring tools to track critical asset health data. That includes conducting regular thermal imaging checks, monitoring vibration levels and oil quality, and carrying out routine checks for air leaks.

eMaint stores, organizes, and analyzes asset health data so managers can access the insights they need. eMaint reporting features can track and trend asset health over time. The software can also cross-analyze asset health and work order data, for a full picture into the cost of owning each machine. eMaint can also automate processes like work order creation, saving time and resources, and ensuring that no job slips through the cracks.

99% Uptime and 100% PM Completion

Amsted Automotive has significantly decreased downtime across the 15 locations that have fully adopted eMaint.

At the company’s plant in Geneva, Illinois, downtime averaged just 1% in December 2024. The same was true at the worksite in Monterrey, Mexico, and at the company’s many other facilities. PM completion was as high as 100% in some Amsted facilities, and the company saw consistent cost savings with the new maintenance approach, totaling significant cost savings per year across the 15 facilities.

Predictive Maintenance

Just as importantly, Amsted Automotive is on the path to a fully data-driven, predictive maintenance strategy. Predictive maintenance is a proven means of increasing asset availability, lowering overall costs, and boosting productivity.

The shift to predictive maintenance took several years and was done in a carefully planned, phased approach, as follows.

Phase One: eMaint adoption

All 15 Amsted Automotive plants achieved full eMaint adoption by the beginning of 2024. That included:

• Consistent work order creation
• PM schedule creation
• MRO strategy development
• Failure analysis
• Predictive maintenance route creation

At this stage, the MRO teams had the tools and data they needed to shift to a proactive maintenance strategy.

Phase Two: Predictive Maintenance Adoption

The 15 Amsted Automotive plants leveraged eMaint analytic and reporting capabilities to implement a predictive maintenance approach which included:

• Monthly root cause analysis
• PM optimization
• Critical spares inventory tracking
• KPI and asset data tracking

Today, the organization has a wealth of data available to all key decision-makers. The MRO team relies on daily “accountability” dashboards and monthly KPIs for at-a-glance insights and overviews of plant operations. MRO teams can see which machines are down, which PMs have been generated for the month, and which work orders still need to be completed.

2025 and Beyond

In the near future, Hahn expects to move to a total reliability solution. Achieving Total Productive Maintenance (TPM) will also entail implementing a complete asset lifecycle management strategy, integrating eMaint with SAP, and realizing organization metrics alignment. Looking ahead, that means greater uptime and productivity, fewer unexpected shutdowns, and much greater operational efficiency for the whole operation.

Your Plant: The Next eMaint Success Story?

eMaint customers consistently report that eMaint customization, customer service, and data analytics deliver the results they need to scale.

Customization: eMaint data tracking, automation, and reporting features can be endlessly customized to meet any organization’s needs.

Customer service: eMaint customer support teams are always available to help managers implement, adjust, and troubleshoot. It’s also easy to train employees and onboard new staff.

Reporting and dashboards: eMaint collects and stores data and makes it easy to create reports that meet your specific needs. The dashboard functionality lets teams easily see trends at a glance and get up to date on new developments quickly.

The bottom line: eMaint flexibility, ease of use, and analytic capabilities make it an essential part of any data-driven maintenance program. The software made it possible for 15 Amsted Automotive facilities to shift to a predictive maintenance approach that provides greater reliability, foresight, and uptime.