Restoring Control and Performance at the Momence Plant

When ReliabilityX began working with the Momence Plant, the situation was critical. OEE had dropped to 40 percent and the plant was entrenched in a reactive culture — leadership and maintenance teams lacked the training needed to drive improvement.

These issues had contributed to a manufacturing variance deficit of $900,000. Every shift was marked by uncertainty, stuck in a cycle of short-term fixes and long-term losses.

ReliabilityX developed a comprehensive maintenance strategy focused on predictive technologies, inventory optimization, and systemic loss elimination — working directly with leadership and staff to build a proactive culture.

1. 1 Implementing predictive maintenance tools to reduce downtime and improve reliability
2. 2 Streamlining on-hand parts inventory to reduce waste and improve responsiveness
3. 3 Delivering targeted training to leadership and technicians to build operational capability
4. 4 Spending time on the floor to resolve minor stops and address root causes in real time

This was not a theoretical exercise. It was a practical, floor-level transformation.

Operational efficiency improved across the board as the plant began recovering from its variance deficit. The shift from reactive to proactive operations created measurable financial and cultural gains.

The plant is now positioned for sustained performance — with stronger leadership, better systems, and a renewed sense of control.