How Leanworx Preventive Maintenance Helped a Company Reduce Unscheduled Breakdowns by 28%

A mid-sized industrial components manufacturer with 100+ CNC machines was facing frequent breakdowns, reactive repairs, and unstable production. Paper-based maintenance schedules meant machines were serviced only after failure, causing long downtime and rising costs. Management believed breakdowns were unavoidable due to heavy utilization. However, deeper analysis showed the real issue was the lack of a structured preventive maintenance system. By implementing automated, usage-based and time-based maintenance with real-time alerts, the company reduced unscheduled breakdowns by 28%, improved OEE, and stabilized throughput — without investing in new machines.