A single line going down for an hour was $100,000 in lost revenue.
Our Challenge
A musical instrument manufacturer, one of the leaders in the industry, saw frequent downtime due to component failures within its finishing systems.
For this manufacturer, a single line going down for an hour was $100,000 in lost revenue.
Alone, the cost of the downtime was extremely high, but in addition to the lost production, the company was paying extra for expedited shipping for the replacement components. Also, the company was using many different parts and components in the finishing system, which made it impossible to have enough replacement parts on hand. It recognized that several of the components it was using were high-risk and were exacerbating the frequent downtime issue.
The company was a longtime customer of OTC Industrial Technologies. It asked OTC to conduct an audit of the system to identify possible solutions.
Our Solution
Working with the manufacturer, the OTC team conducted a detailed audit of the mechanical and electrical systems. The team also reviewed the personnel training, maintenance protocols, and training for equipment use.
During the audit, the team walked the line with the customer to identify the high-risk components and better understand production processes. From the data collected in the audit and walking the line, recommendations for equipment updates and additional training were made.
Where possible, high-risk equipment and components were replaced with more reliable options. In addition, common components and equipment were implemented to reduce the number of spare parts needed and to streamline repairs, especially for high-wear parts. With changes made to the components, a list of recommended spare parts to keep on hand was provided. This would ensure minimal downtime in case of a problem.
Training recommendations were also made. These included adjustments to the maintenance schedule and equipment training. Current processes were documented, problem areas identified, and adjustments were made to maintenance plans to address them.

The Results
The manufacturer now sees quick repairs and easier maintenance. With the upgraded equipment and new maintenance and repair protocols in place, there’s been zero downtime.
After OTC’s recommendations, the manufacturer has seen zero downtime.
Rather than scrambling to make repairs, the operators and maintenance team can focus on production and bigger goals. This has been a welcome benefit of the new training. The upgraded components and access to common spare parts have streamlined maintenance and increased overall production.
Furthermore, since the pandemic, it was a challenge to keep additional technical support resources at the facility. With the new equipment and key learnings from the audit, there is significantly less unplanned emergency work for those already overworked resources. Instead of continually struggling to maintain or repair those systems, the technical and maintenance team can shift to other work and priorities, a powerful benefit of the project.
After the work, OTC is also able to better support the manufacturer. OTC works closely with the facility, integrated with and operating more like a member of the team in assisting production and providing maintenance support at the site.
With the completion of the site audit and upgrades, the manufacturer has begun planning future finishing system upgrades with OTC.